How it Works
Perkins Engine
Loading...
1106C  

Perkins Engine 1106C   Service Manual

Download
Page 1
Operation and Maintenance Manual
SEBU8387
May 2007
1106C Genset
(Engine)
PK
Page 2
Page 3
SEBU8387 3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 5
General Hazard Information ................................... 7
Burn Prevention ...................................................... 9
Fire Prevention and Explosion Prevention .............. 9
Crushing Prevention and Cutting Prevention ......... 11
Mounting and Dismounting .................................... 11
High Pressure Fuel Lines ..................................... 12
Before Starting Engine .......................................... 13
Engine Starting ..................................................... 13
Engine Stopping ................................................... 14
Maintenance In
Warranty Secti
Warranty Information ............................................ 87
terval Schedule ............................ 53
on
Index Section
Index ..................................................................... 88
Electrical System .................................................. 14
Engine Electronics ................................................ 15
Product Information Section
General Information .... .......................................... 17
Model Views ......................................................... 18
Product Identification Information ........................ 22
Operation Section
Lifting and Storage ................................................ 24
Gauges and Indic ators .......................................... 26
Features and Controls .......................................... 28
Engine Diagnostics ............................................... 34
Engine Starting ..................................................... 38
Engine Operation .................................................. 41
Engine Stopping ................................................... 42
Cold Weather Operation ....................................... 44
Maintenance Section
Refill Capacities .................................................... 48
Page 4
4 SEBU8387 Foreword
Foreword
Literature Information
This manual con lubrication and maintenance information. This manual should be stored in or near the engine area in a literatur study and keep it with the literature and engine information.
English is the primary language for all Perkins publications. The English used facilitates translation and consiste
Some photographs or illustrations in this manual show details from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvemen may have caused changes to your engine which are not included in this manual. Whenever a question arises reg consult with your Perkins dealer or your Perkins distributor for the latest available information.
Safety
This safety section lists basic safety precautions. In addition, this section identifies hazardous, warning si precautions listed in the safety section before operating or performing lubrication, maintenance and repair on
this product.
tains safety, operation instructions,
e holder or literature storage area. Read,
ncy.
or attachments that may be different
t and advancement of product design
arding your engine, or this manual, please
tuations. Read and understand the basic
Recommended se appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine a Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequen specified in the Maintenance Interval Schedule may be necessary.
The maintenance schedule items are organized for a preventive maintenance management program. If the prevent periodic tune-up is not required. The implementation of a preventive maintenance management program should mini avoidances resulting from reductions in unscheduled downtime and failures.
ive maintenance program is followed, a
mize operating costs through cost
rvice should be performed at the
lso governs the Maintenance Interval
t lubrication and maintenance than is
Maintenance Intervals
Perform maintenance on items at multiples of the original requirement. We recommend that the maintenan near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of
Your authorized Perkins dealer or your Perkins distribu maintenance schedule to meet the needs of your operating environment.
ce schedules be reproduced and displayed
the engine’s permanent record.
tor can assist you in adjusting your
Overhaul
Operatio
Operating techniques outlined in this manual are basic. Th techniques required to operate the engine more efficiently and economically. Skill and techniques develop engine and its capabilities.
The oper Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and sto discussion of electronic diagnostic information.
n
ey assist with developing the skills and
as the operator gains knowledge of the
ation section is a reference for operators.
pping the engine. This section also includes a
Maintenance
The mai The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance interv referenced to detailed instructions that follow.
ntenance section is a guide to engine care.
als. Items in the maintenance schedule are
Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the i interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your P regarding overhaul programs. If you experience a major engine failure, there are also numerous after f your Perkins dealer or your Perkins distributor for information regarding these options.
nterval and the maintenance items in that
erkins distributor offers a variety of options
ailure overhaul options available. Consult with
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,
defects, and other reproductive harm. Battery
birth posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
Page 5
SEBU8387 5
Safety Section
Safety Messages
Safety Section
i02648377
Safety Messages
There may be s engine. The exact location and a description of the warning signs are reviewed in this section. Please become famil
Ensure that all of the warning signs are legible. Clean the warning s the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning si could drop off of the engine.
Replace an missing.Ifawarningsignisattachedtoapartofthe engine that is replaced, install a new warning sign on the replac distributor can provide new warning signs.
everal specific warning signs on your
iar with all warning signs.
igns or replace the warning signs if
signs. Do not use solvents, gasoline, or
gns. The warning signs that are loosened
y warning sign that is damaged or
ement part. Your Perkins dealer or your
(1) Universal Warning
Do not operate or work on this equipment unless you have r and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the or death.
ead and understand the instructions
warnings could result in s erious injury
Illustration 1
lexample
Typica
The Universal Warning label (1) is located on both sides o
f the valve mechanism cover base.
g01154807
Page 6
6 SEBU8387 Safety Section Safety Messages
Illustration 2
Location of label
(1) Universal warning
(2) Ether Warning
Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.
g01329365
Illustration 3
Typical exam ple
g01154809
The ether warning label (2) is located on the cover of the inlet manifold.
Page 7
SEBU8387 7
Safety Section
General Hazard Information
Illustration 4
Location o
(2) Ether (3) Hand (High Pressure)
f labels
(3) Hand (High Pressure)
Contact penetration and burn hazards. High pressure fu­el spray may cause a fire hazard. Failure to fol­low thes structions may cause personal injury or death.
with high pressure fuel may cause fluid
e inspection, maintenance and service in-
g01329366
The warning label for the Hand (High Pressure) (3) is located o
n the top of the fuel manifold.
i023284
General Hazard Information
35
Illustration 5
lexample
Typica
g01154858
Illustration 6
g0010
Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls
e you service the equipment or before you
befor repair the equipment.
4545
Page 8
8 SEBU8387 Safety Section General Hazard Information
Illustration 7
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 f rom foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps.
g00702020
When pressuriz cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protectiv
The maximum air pressure for cleaning purposes must be below water pressure for cleaning purposes must be below 275 kPa (40 psi).
ed air and/or water is used for
efaceshield.
205 kPa (30 psi). The maximum
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydrau escape rapidly if the pressure is not relieved correctly.
Do not remove until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve th
lic fluid or items such as pipe plugs to
any hydraulic components or parts
or parts until pressure has been relieved
e hydraulic pressure.
Never put maintenance fluids into glass containers. Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care.
Report all necessary repairs.
Do not allow unauthorized personnel on the equipment.
Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs.
Perform maintenance on the engine with the equipment in the servicing position. Refer to the OEM information for the procedure for placing the equipment in the servicing position.
Pressure Air and Water
Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury.
The direct application of pressurized air or pressurized water to the body could result in personal injury.
Illustration 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 fluid with a suitable container before any compartment is opened or before any component is disassembled.
Only use the tools that are suitable for collecting
•
fluids and equipment that is suitable for collecting fluids.
Page 9
SEBU8387 9
Safety Section
Burn Prevention
Only use the too
•
fluids and equipment that is suitable for containing fluids.
Obey all local regulations for the disposal of liquids.
ls that are suitable for containing
i02334785
Burn Prevention
Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu­el spray may cause a fire hazard. Failure to fol­low these inspection, maintenance and service in­structions may cause personal injury or death.
After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines.
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.
i02320721
Fire Prevention an d Explosion Prevention
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 withabarehand.Removethefiller cap slowly in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.
tion 9
Illustra
All fuels, most lubricants, and some coolant mixtures are flamma
Flammable fluids that are leaking or spilled onto hot surfaces 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 remo
Determinewhethertheenginewillbeoperatedinan environ drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, proper
If the application involves the presence of combustible gases, Perkins distributor for additional information about suitable protection devices.
ble.
or onto electrical components can cause
ved.
ment that allows combustible gases to be
ty damage, or engine damage could result.
consult your Perkins dealer and/or your
g00704000
Page 10
10 SEBU8387 Safety Section Fire Prevention and Explosion Prevention
Remove all flamm
able combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any flammable combustible materials or c
onductive materials to accumulate on
the engine.
Store fuels a
nd lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers.
Do not smoke in areas that are used for
storing flammable materials.
Do not expose
theenginetoanyflame.
Exhaust shields (if equipped) protect hot exhaust components f
rom oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain flammable fl
uid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting.
Wiring must be kept in good condition. All electrical wires must be correctly routed and securely attached. Check all e
lectrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all elect
rical connections.
Oil filters and f
uel filters must be correctly installed. The filter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for mor
Illustration 10
e information.
g00704059
Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling.
Eliminate all wiring that is unattached or unnecessary. Do not use
any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure connections, recommended wiring, and correctly maintai
ned battery cables will help to prevent arcing
or sparking.
Contact with high pressure fuel may cause fluid penetra
tion and burn hazards. High pressure fu­el spray may cause a fire hazard. Failure to fol­low these inspection, maintenance and service in-
ions may cause personal injury or death.
struct
After the engine has stopped, you must wait for 60 second
s in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines.
Ensure that the engine is stopped. Inspect all lines and hoses for wear or for deterioration. The hoses must be
correctly routed. The lines and hoses must
have adequate support and secure clamps.
Illustration 11
g00704135
Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas.
Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or ahydrometer.
Page 11
SEBU8387 11
Safety Section
Crushing Prevention and Cutting Prevention
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. This may cause an explosion.
The batteries must be kept clean. The covers (if equipped recommended cables, connections, and battery box covers when the engine is operated.
er cable connections can cause
.
)mustbekeptonthecells.Usethe
Fire Extinguisher
Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fi extinguisher regularly. Obey the recommendations on the instruction plate.
re 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.
Leaks can cause fires. Consult your Perkins dealer or your Per
Replace the parts if any of the following conditions are presen
kins distributor for replacement parts.
t:
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. Leave 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 a re struck, wear protective glasses in order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be i
the guards in place until maintenance
njured by flying debris.
ntion
i02235492
Mounting and Dismounting
High pressure fuel line or lines are removed.
•
End fittings are damaged or leaking.
•
Outer cove
•
Wires are exposed.
•
Outer coverings are ballooning.
•
Flexible p
•
Outer covers have embedded armoring.
•
End fittings are displaced.
•
Make sure t are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other parts, an
rings are chafed or cut.
art of the hoses are kinked.
hat all clamps, guards, and heat shields
d excessive heat.
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 12
12 SEBU8387 Safety Section High Pressure Fuel Lines
i02668808
High Pressure Fuel Lines
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu­el spray may ca low these inspection, maintenance and service in­structions may cause personal injury or death.
use a fire hazard. Failure to fol-
Illustration 1 2
(1)Highpressureline (2)Highpressureline (3)Highpressureline
(4) High press u re line (5) High press u re line (6) High press u re 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:
g01341328
(7) High pressure fuel manifold (rail) (8) High pressure line
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.
Page 13
SEBU8387 13
Safety Section
Before Starting Engine
Donotsteponth deflect the high pressure fuel lines. Do not bend or strike the high pressure fuel lines. Deformation or damage of the h point of weakness and potential failure.
Do not check t engine or the starting motor in operation. After the engine has stopped allow 60 seconds to pass in order to allow the p or repair is performed on the engine fuel lines.
Do not loosen 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 a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.
Inspect the high pressure fuel lines for damage,
•
deformation, a nick, a cut, a crease, or a dent.
Do not operate the engine with a fuel leak. If there
•
isaleakdonottightentheconnectioninorder to stop the tightened to the recommended torque. Refer to Disassembly and Assembly, “Fuel injection lines ­Remove an
If the high pressure fuel lines are torqued correctly
•
and the hi high pressure fuel lines must be replaced.
e high pressure fuel lines. Do not
igh pressure fuel lines may cause a
he high pressure fuel lines with the
ressure to be purged before any service
thehighpressurefuellinesinorder
inspection procedure in order to avoid
leak. The connection must only be
d Fuel injection lines - Install”.
gh pressure fuel lines are leaking the
i02322199
Before Starting Engine
The initial sta or repaired make provision to shut the engine off, in order to stop an overspeed. This may be accomplished supply to the engine.
Overspeed shu engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop button in ord
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
If equipped, ensure that the lighting system for the engine is su lights work correctly, if equipped.
All protect be installed if the engine must be started in order to perform service procedures. To help prevent an accident t around the parts carefully.
Do not bypa disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits engine damage.
rt-up of an engine that is new, serviced
by shutting off the air and/or fuel
tdown should occur automatically for
er to cut the fuel and/or air to the engine.
of personnel.
itable for the conditions. Ensure that all
ive guards and all protective covers must
hat is caused by parts in rotation, work
ss the automatic shutoff circuits. Do not
are also provided in order to help prevent
Ensure th
•
are in place. Do not operate the engine with clips that are damaged, missing or loose.
Do not attach any other item to the high pressure
•
fuel lines.
Loosened high pressure fuel lines must be
•
replaced. Also removed high pressure fuel lines must be r assembly manual, “ Fuel Injection Lines - Install”.
at all clips on the high pressure fuel lines
eplaced. Refer to Disassembly and
See the Se adjustments.
rvice Manual for repairs and for
i02251260
Engine Starting
Do not use aerosol types of starting aids such as ether. Such use could result i n 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.
Page 14
14 SEBU8387 Safety Section Engine Stopping
All protective be installed if the engine must be started in order to perform service procedures. To help prevent an accident that around the parts carefully.
Start the eng from the engine start switch.
Always start that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Kno prevent major damage to the engine components. Knowing the procedure will also help to prevent personal in
To ensure that the jacket water heater (if equipped) and/or the l correctly, check the water temperature gauge and/or the oil temperature gauge during the heater operation
Engine exhaust contains products of combustion which can b engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the e
Note: The engine is equipped with a device for cold starting conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the corre operation.
guards and all protective covers must
is caused by parts in rotation, work
ine from the operator’s compartment or
the engine according to the procedure
wing the correct procedure will help to
jury.
ube oil heater (if equipped) is working
.
e harmful to your health. Always start the
ngine exhaust to the outside.
. If the engine will be operated in very cold
ct type of starting aid for your region of
Stop the engine during the initial start-up of a new engine or an engine that has been overhauled.
To stop an electronically controlled engine, cut the power to the engine and/or shutting off the air supply to the engine
if an overspeed condition occurs
.
i02234878
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 cabletotheengineblock.
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.
These en aid in each individual cylinder that heats the intake air in order to improve starting.
ginesareequippedwithaglowplugstarting
i02234873
Engine Stopping
Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components.
Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.
Page 15
SEBU8387 15
Safety Section
Engine Electronics
Grounding Practices
Illustration 13
Typical exam ple
(1) Starting motor to engine block (2) Ground to starting motor (3) Ground to battery
g01162916
Uncontrolled e
lectrical circuit paths can result in damage to the crankshaft bearing journal surfaces and to aluminum components.
Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge.
To ensure that the engine and the engine electrical systems func
tion correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This path may be provided by way of a direct engine groun
d to the frame.
The connections for the grounds should be tight and free of corro
sion. The engine alternator must be grounded to the negative “-” battery terminal with a wire that is adequate to handle the full charging current of t
he alternator.
The power supply connections and the ground connectio
ns for the engine electronics should always
be from the isolator to the battery.
i02650954
Engine Electro nics
Illustration 14
Typical exam ple
(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.
Tamper ing
with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine da
mage.
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:
Warning
•
Page 16
16 SEBU8387 Safety Section 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 Speed/
•
Intake Manifold Air Temperature
•
The Engine Monitoring package can vary for different engine models and different engine applications. However, the m monitoring control will be similar for all engines.
Note: Many of modules that are available for Perkins Engines will work in unison with the Engine Monitoring System. Tog et he r, t monitoring function for the specific engine application. Refer to Troubleshooting for more information on the Engine Moni
Timing
onitoring system and the engine
the engine control systems and display
he two controls will provide the engine
toring System.
Page 17
SEBU8387 17
Product Information Section
General Information
Product Information Section
General Information
i01889424
Welding on Engines with Electronic Controls
NOTICE Proper welding procedures are necessary in order to avoid damage to the engine’s ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the compo­nent. If removal of the component is not possible, the following procedure must be followed when you weld with a unit that is equipped with an Electronic Engine. The following procedure is considered to be the safest procedure to weld a component. This pro­cedure should provide a minimum risk of damage to electronic components.
NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other 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.
1. Stop the engine. Turn the switched power to the
OFF position.
2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided, open the switch.
Illustration 15
Use the example above. The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components.
(1) Engine (2) Welding rod (3) Keysw itch in the OFF position (4) Battery disconnect switch in the open position (5) Disconnected battery cables (6) Battery (7) Electrical/Electronic com ponent (8) Maximum distance between the component that is being
welded and any electrical/electronic component (9) The component that is being welded (10) Current path of the welder (11) Ground clamp for the welder
4. Connect the welding ground cable directly to the
part that will be welded. Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings, hydraulic components, electrical components, and ground straps.
Note: If electrical/electronic components are used as a ground for the welder, or electrical/electronic components are located between the welder ground and the weld, current fl ow from the welder could severely damage the component.
g00765012
3. Disconnect the J1/P1 connectors from the ECM. Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins.
5. Protect the wiring harness from welding debris and spatter.
6. Use standard welding practices to weld the materials.
Page 18
18 SEBU8387 Product Information Section Model Views
Model Views
i02649396
Model View Illustrations
The following model views show typical features of the engine. engine may appear different from the illustrations.
Due to individual applications, your
Note: Only maj
or components are identified on the
following illustrations.
Illustration 1 6
Front left engine view
(1) Fuel manifold ( Rail) (2) Canister for the crankcase breather (3) Electronic control module (4) P2 connector (5) Secondary fuel filter
(6) Hand primer (7) Pr imary f u el filter (8) Oil sampling valve (9) Oil fi lter (10) Fuel pump
g01329939
(11) Water p ump (12) Damper (13) Fan (14) Fan pulley (15) Belt tensioner
Page 19
SEBU8387 19
Product Information Section
Model Views
Illustration 1 7
Rear right engine view
(16) Oil gauge (17) Air intake (18) O il filler (19) Front lifting eye (20) Alternator
(21) Exhaust manifold (22) Exhaust elbow (23) Turbocharger (24) Wastegate solenoid (25) Starting motor
i02715685
Engine Description
The 1106 Electronic Engine model PK is designed for the following applications: machine and industrial mobile equipment. The engine is available in the following type of aspiration:
Turbocharged aftercooled
•
Four stroke cycle
•
In-line 6 cylinder
•
g01329941
(26) Oil pan (27) Drain plug (oil) (28) Drain plug or coolant sampling valve (29) Breather (30) Rea r lifting eye
Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right sides of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder.
Page 20
20 SEBU8387 Product Information Section Model Views
Illustration 18
1106 Electronic Engine model PK
(A) Ex haust valves (B) Inlet valves
Table 1
1106 Electronic Engine Model PK Specifications
Operating Range (rpm)
Number of Cylinders 6 In-Line
Bore
Stroke 127 mm (5.0 inch)
Aspiration
Compression Ratio 16.2:1
Displacement 6.6 L (403 in3)
Firing Order 1-5-3-6-2-4
Rotation (fl
Valve Lash Setting (Inlet) 0.35 mm (0.013 inch)
Valve Lash Setting (Exhaust)
(1)
The o perating rpm is dependent on the engine rating, the
application and the configuration of the throttle.
ywheel end)
900 to 2800
105 mm (4.13 inch)
Turbocharged aftercooled
Counterclo
0.35 mm (0.013 inch)
g01127295
(1)
ckwise
Electronic Engine Features
Automatic air/
•
Torque rise shaping
•
Injection timing control
•
System diagno
•
fuel ratio control
stics
For more information on electronic engine features, refer to the Op
eration and Maintenance Manual,
“Features and Controls” topic (Operation Section).
Engine Diagnostics
The engine has that the engine systems are functioning correctly. The operator will be alerted to the condition by a “Stop or Warning” lam horsepower and the vehicle speed may be limited. Theelectronicservicetoolmaybeusedtodisplay the diagnos
There are three types of diagnostic codes: active, logged, and
Most of the diagnostic codes are logged and stored in the ECM. F 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 desired en
Engine Coo
The cooling system consists of the following component
Gear-driven centrifugal water pump
•
Water temperature regulator which regulates the
•
engine coolant temperature
built-in diagnostics in order to ensure
p. Under certain conditions, the engine
tic codes.
event.
or additional information, refer to
gine rpm.
ling and Lubrication
s:
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 governing
•
Control of the injection pressure
•
Cold start strategy
•
Gear-driven rotor type oil pump
•
Oil cooler
•
The engine lubricating oil is supplied by a rotor type oil pump.
The engine lubricating oil is cooled and the engine lubricating oil is filtered. The bypass valve can provide unrestricted flow of lubrication oil to the engin
e if the oil filter element should become
plugged.
Page 21
SEBU8387 21
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, e fficiency of emission controls, and
mance and efficiency also depend on
ntenance Interval Schedule” for more
Page 22
22 SEBU8387 Product Information Section Product Identification Information
Product Identification Information
Plate Locations and Film Locations
i02761892
Serial Number Plate (1)
Theengineserialnumberplateislocatedonthe left side of the cylinder block to the rear of the front engine mounting.
on 20
Illustrati
Serial number plate
g01094203
i02164876
Reference Numbers
Illustration 19
Location of the serial number plate
g01331472
Perkins engines are identified by an engine serial number.
An example of an engine number is PK*****U000001J.
*****
____________________ The list number for the engine
__________________________________________ Type of engine
PK
____________________________Built in the United Kingdom
U
000001
J
___________________________ Engine Serial Number
_____________________________________ Year of Manufacture
Perkins dealers or Perkins distributors need all of these numbers in order to determine the components that were included with the engine. This permits accurate identification of replacement part numbers.
The numbers for fuel setting information for electronic engines are stored within the flash file. These numbers can be read by using the electronic service tool.
Informatio
n for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Makeacopyo
f this list for a record. Keep the
information for future reference.
Record for Reference
_______________________________________________
Engine Mod
Engine Serial number _____________________________________
Engine Low Idle rpm ______________________________________
Engine Ful
Primary Fuel Filter _________________________________________
Water Separator Element ______ __________________________
Secondary
Lubrication Oil Filter Element ___________________________
Auxiliary Oil Filter Element _______________________________
Tot a l Lu br
Total Cooling System Capacity _________________________
el
l Load rpm
Fuel Filter Element
_____________________________________
__________________________
ication System Capacity
_____________________
Air Cleaner Element _______________________________________
Page 23
SEBU8387 23
Product Information Section
Product Identification Information
Fan Drive Belt _
_____________________________________________
Alternator Belt ______________________________________________
i02648170
Emissions Certification Film
Label for compliant engines
Typical examp
les of emissions labels
Illustration 2 1
g01329012
Page 24
24 SEBU8387 Operation Section Lifting and Storage
Operation Section
Lifting and Storage
Engine Lifting
i02164186
Some removals r obtain correct balance and safety.
To r em ov e t h e e are on the engine.
Lifting eyes a engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obso that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information lifting.
equire lifting the fixtures in order to
ngine ONLY, use the lifting eyes that
re designed and installed for specific
lete. If alterations are made, ensure
regarding fixtures for correct engine
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 the eyeb ber that the capacity of an eyebolt is less as the angle between the supporting members and the object be­comes le
When it is necessary to remove a component at an angle, o the weight.
Use a ho an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parall be perpendicular to the top of the object that is being lifted.
olts and the brackets under tension. Remem-
ss than 90 degrees.
nly use a link bracket that is properly rated for
ist to remove heavy components. Use
el to each other. The chains and cables should
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 25
SEBU8387 25
Operation Section
Lifting and Storage
Personal injury can result from hot coolant. Any contact with hot coolan t or with steam can 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.
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.
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 BDC 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 filte Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spray is printed on with waterproof tape.
14. Remove the the turbocharger. Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spray i turbocharger with waterproof tape.
15. Seal the ve with waterproof tape.
16. Remove the belt into storage.
17. In order t of the engine, spray the engine with 1734115 POWERPART Lay-Up 3. Do not spray the area inside th
e alternator.
place the crankcase breather
ve mechanism cover. Spray
.Spray1762811 POWERPART
r assembly and the turbocharger.
the container. Seal the turbocharger
exhaust pipe from the output side of
s printed on the container. Seal the
nt of the fuel tank or the fuel filler cap
alternator drive belt and put the drive
o prevent corrosion to the outside
Fill the oil pan to the Full Mark on the engine oil level gauge with new, clean lubricating oil. Add 1762811 POWERPARTLay-Up2totheoilin order t o 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 POWERP ART Lay-Up 3 can be used on the terminals. Put the battery into safe storage.
Page 26
26 SEBU8387 Operation Section Gauges and Indicators
Gauges and Indicators
i02717240
Gauges and Indicators
Your engine m the gauges that are described. For more information about the gauge package, see the OEM information.
Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine th the gauges over a period of time.
Noticeable c potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the r Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer or your Per
Some engine applications are equipped with Indicator Lamps. Ind 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 indica
•
current operational status of the engine. The indicator lamps can also indicate that the engine has a faul via the ignition switch.
The indic
•
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:
ay not have the same gauges or all of
e normal operating range by observing
hanges in gauge readings indicate
eadings are within specifications.
kins distributor for assistance.
icator lamps can be used as a diagnostic
torlampscanbeusedtoidentifythe
t. This system is automatically operated
ator lamps can be used to identify active
NOTICE
Engine Oil Pressure – The 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 C
Typical temperature range is 83° to 95°C
(181.4° to 171°F). The maximum allowable temperature a system at 48 kPa (7 psi) is 103 °C (217.4 °F). Higher temperatures may occur under certain conditions. The water tem to load. The temperature reading should never exceed 7 °C (44.6 °F) below the boiling point for the pressurized
A 100 kPa (14.5 psi) radiator cap may be installed on the cooling system. The temperature of this cooling system must n
If the engine is operating above the normal range and steam be procedure:
1. Reduce the l
2. Determine if the engine must be shut down
immediatel reducing the load.
3. Inspect the
load, the engine is running at high idle. The engine is running at 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.
system that is being used.
Tachometer – This gauge indicates engine
speed (rpm
ismovedtothefullthrottlepositionwithout
thefullloadrpmwhenthethrottlecontrol
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
.
oolant Temperature –
t sea level with the pressurized cooling
perature reading may vary according
ot exceed 112 °C (233.6 °F).
comes apparent, perform the following
oad and the engine rpm.
y or if the engine can be cooled by
cooling system for leaks.
). When the throttle control lever
NOTICE
Page 27
SEBU8387 27
Operation Section
Gauges and Indicators
Service Hour M eter – The gauge indicates total operating hours of the engine.
Page 28
28 SEBU8387 Operation Section Features and Controls
Features and Controls
i02651062
Monitoring System
If the Shutdown mode has been selected and the warning indi take as little as 20 seconds from the time the warn­ing indicator is activated. Depending on the ap­plication, s avoid personal injury. The engine can be restarted following shutdown for emergency maneuvers, if necessary.
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
•
cator activates, engine shutdown may
pecial 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 power begin to flash when the derating occurs.
Theenginewi preset operational limits. The engine derate is achieved by restricting the amount of fuel that is available f reduction of fuel is dependent on the severity of the fault that has caused the engine derate, typically up to a limit o predetermined reduction in engine power.
“Warning/
The “Diagnostic” lamp turns “ON” and the warning signal (re the engine power will be derated. The engine will continue at the rpm of the set derate until a shutdown of the engi after a shutdown for use in an emergency.
A shutdow as 20 seconds. The engine can be restarted after a shutdown for use in an emergency. However, the cause Theenginemayshutdownagaininaslittleas20 seconds.
will be derated. The warning lamp will
ll be derated if the engine exceeds
or each injection. The amount of this
f 50%. This reduction in fuel results in a
Derate/Shutdown”
d lamp) is activated. After the warning,
ne occurs. The engine can be restarted
n of the engine may occur in as little
of the initial shutdown may still exist.
Engine speed/timing
•
Programmable Options and Systems Operation
If the Warning/Derate/Shutdown mode has been selected and the warning indicator activates, bring the engine to a stop whenever possible. 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 order to
For each of the programmed modes, refer to Trouble information on Indicator Lamps.
For more your Perkins dealer or your Perkins distributor.
verify the condition.
shooting , “Indicator Lamps” for more
information or assistance for repairs, consult
Page 29
SEBU8387 29
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
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 fault has b
een detected.
The engine has not been started.
Theengineisrunning normally.
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.
i02649763
Sensors and Electrical Components
Sensor Locations
tion 23 shows the typical locations of the
Illustra sensors on the engine. Specific engines may appear different from the illustration due to differences in applicat Module (ECM) is illustrated.
ions. The location of the Electronic Control
Page 30
30 SEBU8387 Operation Section Features and Controls
Illustration 2 3
(1) Coolant temperature sensor (2) Intake manifold air temperature sensor (3) Intake m anifold pressure sensor
(4) Fuel pressure sensor (5) Electronic control module (ECM) (6) Oil pressure sensor
g01330217
(7) Primary position sensor (8) Secondary position sensor
Page 31
SEBU8387 31
Operation Section
Features and Controls
Illustration 2 4
(1) Coola (2) Intak
nt temperature sensor
e manifold air tem perature sensor
e manifold pressure sensor
(3) Intak (4) Fuel p
ressure sensor
ronic control module (ECM)
(5) Elect
g01330220
Illustration 2 5
(6) Engine oil pressure sensor (7) Primary speed/timing sensor (8) Secondary speed/timing sensor
g01330325
Page 32
32 SEBU8387 Operation Section Features and Controls
Illustration 2 andtheECMinpositionontheengine.
4 and illustration 25 shows the sensors
Failure of Sensors
All Sensors
A failure of any of the sensors may be caused by one of the followi
Sensor output is open.
•
Sensor output is shorted to “- battery” or “+ battery”.
•
Measured read
•
specification.
ng malfunctions:
ing of the sensor is out of the
Programmable Monitoring System (PMS)
The Programmable Monitoring System determines the level of a Module (ECM) (5) in response to a condition that can damage the engine. These conditions are identified by the ECM fr the following sensors.
ction that is taken by the Engine Control
om the signals that are produced from
Failure of the C
oolant Temperature
Sensor
The ECM (5) wil temperature sensor. The diagnostic lamp will warn the operator about the status of the coolant temperature sensor. A fai will not cause a shutdown of the engine or any horsepower change. In order to check the correct operation of “Engine Temperature Sensor Circuit - Test”.
l detect a failure of the coolant
lure of the coolant temperature sensor
the sensor, refer to Troubleshooting,
Intake Manifold Air Temperature Sensor 2
The intake manifold air temperature sensor measures the intake a ECM (5). The intake manifold air temperature sensor is also used by the ECM to determine initiation of the Cold Start
In order to check the correct operation of the sensor, refer to Tr Circuit - Test”.
ir temperature. A signal is sent to the
Strategy.
oubleshooting, “EngineTemperature Sensor
Intake Manifold Pressure Sensor 3
Coolant Tem
•
Intake manifold Air Temperature Sensor
•
Intake manifold Pressure Sensor
•
Fuel Pressu
•
Engine Oil Pressure Sensor
•
Primary Speed/Timing Sensor
•
Secondary S
•
Coolant Tem
The coolant temperature sensor monitors engine coolant tem indicate a high coolant temperature through a relay or a lamp. The coolant temperature sensor is used by the ECM t Condition.
perature Sensor
re Sensor
peed/Timing Sensor
perature Sensor 1
perature. The output of the ECM (5) can
o determine initiation of the Cold Start
The intake pressure in the manifold. A signal is sent to the ECM (5).
manifold pressure sensor measures
Fuel Pressure Sensor 4
The fuel pressure sensor measures the fuel pressure in the fuel manifold. A signal is sent to the ECM (5).
Engine O il Pr essure Sensor 6
The engine oil pressure sensor is an absolute pressure sensor that measures the engine oil pressure pressure sensor detects engine oil pressure for diagnostic purposes. The engine oil pressure sensor sends a s
Low Oil Pressure Warning
The setpoint for the low pressure warning is dependent upon the engine speed. The fault will be active a for more than 8 seconds.
in the main oil gallery. The engine oil
ignal to the ECM (5).
nd logged only if the engine has been running
Page 33
SEBU8387 33
Operation Section
Features and Controls
Very Low Oil Pre
The very low oil pressure setpoint is dependent upon the engin engine monitoring system is selected, the ECM (5) will derate the engine power. The engine horsepower will be limit
ed.
ssure Warning
e speed. If the DERATE mode of the
Failure of th e Engine Oil Pressure Sensor
The ECM (5) will detect failure of the engine oil pressure sensor. The diagnostic lamp warns the user about the sta The engine oil pressure related strategies will be disabled in the event of a failure of the engine oil pressure sen sensor will not cause a shutdown of the engine or any horsepower change. In order to check the correct operation o Volt Sensor Supply Circuit - Test”.
tus of the engine oil pressure sensor.
sor. A failure of the engine oil pressure
f the sensor, refer to Troubleshooting, “5
Primary Speed/Timing Sensor 7
If the ECM ( primary speed/timing sensor , the “DIAGNOSTIC” lamp will indicate a diagnostic fault code which will be logged in t
5) does not receive a signal from the
he ECM memory.
Secondary Speed/Timing Sensor 8
The signal from the secondary speed/timing sensor is used by the ECM (5) on engine start-up in order to check the stroke of the pistons. The secondary speed/timing sensor may be used by the ECM in order to operate the engine if the primary speed/timing sensor is faulty.
In order to check the correct operation of the sensor, refer to Troubleshooting, “Engine speed/Timing sensor-Test”.
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.
If the ECM does not receive a signal from the primary speed/tim from the secondary speed/timing sensor (8). The ECM continually checks in order to determine if there is a signa
Intermittent failure of the sensors will cause erratic engine co
ing sensor (7), the ECM will read the signal
l from both sensors.
ntrol.
Failure o f the Primary Speed/Timing Sensor
Correct operation of the primary speed/timing sensor i against reverse running of the engine. If the primary speed/timing sensor fails there is no automatic protect applications, it is possible for the transmission to run the engine in reverse. In this event, Stop the engine position.
In orde refer to Troubleshooting, “Engine speed/Timing sensor - Test”.
s essential. Software in the ECM protects
ion against reverse running. In some
immediately. Turn the keyswitch to the “OFF”
r to check the correct operation of the sensor,
Page 34
34 SEBU8387 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 an activ Lamps” for more information. A fault diagnostic code will remain active until the problem is repaired. The dia electronic service tool. Refer to Troubleshooting , “Electronic Service Tools” for more information.
e fault. Refer to Troubleshooting , “Indicator
gnostic code may be retrieved by using the
i02761893
Diagnostic Flash Cod e 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. Move the keyswitch from the on/off two times
within three
A flashing YELLOW lamp indicates a 3 digit code for the engine. T system diagnostic message. Count the first sequence of flashes in order to determine the first digit of the flash code. A sequence of flashes will identify the second digit of the flash code. After the second pause, the third sequence of
Any additional flash codes will follow after a pause. These code Flash Code 551 indicates that No Detected Faults have occurred since the ignition keyswitch has been turned to t
For further information, assistance for repairs, or troubles consult your Perkins distributor.
Table3 li brief description of the flash codes.
Note: Ta b performance with “ACTIVE” flash codes.
Some code may also indicate that a mechanical system needs attention. Troubleshooting is not required for code “551”. Co codes will limit the operation or the performance of the engine.
Table3 indicates the potential effect on the engine performance with active flash codes. Table 3 also forms a l descriptions.
hooting, refer to the Service Manual or
sts the flash codes and the table also gives a
seconds.
he sequence of flashes represents the
fter a two second pause, the second
flashes will identify the flash code.
s will be displayed in the same manner.
he ON position.
le3 indicates the potential effect on engine
s record events. Also, some codes
de 001 will not display a flash code. Some
ist of Electronic diagnostic codes and
Page 35
SEBU8387 35
Operation Section
Engine Diagnostics
Table 3
Flash Codes for 1106C Genset
Diagnostic
Effect On Engine Performance
Flash Code
Description Engine
Misfire
Low
Power
Reduced
Engine
Speed
111 No. 1 Injector Fault X X X
112 No. 2 Injector Fault X X X
113 No. 3 Injector Fault X X X
114 No. 4 Injector Fault X X X
115 No. 5 Injector Fault X X X
116 No. 6 Injector Fault X X X
133
Intake Manif
old Air
XX
Temperature sensor
(5)
fault
135 Intake Manifold Boost
XX
Pressure Fault
141 Primary Engine
XX
Speed/Timing Sensor
(6)
Fault
142
Secondary Engine Speed/Timing Sensor Fault
143 Engine Timing
XX
Calibration Fault
144
Engine Operation Mode
XX
Selector Switch Fault
154 Throttle Position sensor
XX
Fault
155
157
Secondary Throttle Position
sensor Fault
Engine Oil Pressure
XX
XX
Sensor Fault
159 Fuel Rail Pressure
XX
Sensor Fault
162 Fuel Rail Pressure
XX X
Valve Solenoid Fault
168 Engine Coolant
Temperature Sensor Faul
177 Turbo Wastegate
X
Actuator Fault
199
Glow Plug Start Relay Fault
415
Software Mismatch
422 ECM Power Supply
XX X X
XX X
Voltage Fault
(1)
(2)
Suggested Operator Action
Engine
Shutdown
Service
(3)
Schedule
a Service.
(4)
X
X
X
(continued)
Page 36
36 SEBU8387 Operation Section Engine Diagnostics
(Table 3, contd)
439
514 SAE J1939 Data Link
516
517
527
(1)
If warning lamps are installed refer to this table. For installations that have electronic displays, refer to the OEM for inform ation.
(2)
An “X” indicates that the effect on engine performance may occur if the c ode is ac tive.
(3)
The operator should go to the nearest location that has a qualified service program.
(4)
Schedule Service: The problem should be investigated w hen the operator has access to a qualified service program.
(5)
These Flash Codes may affect the system under specific environmental conditions such as engine start-up at cold temperature and
cold weather operation at high altitudes.
(6)
If the primary engine speed/timing sensor fails there is no automatic protection against reverse running. In this event, Stop the engine immediately. Turn the keyswitch to the “OFF” po sition. In order to check the correct operation of the sensor, refer to Troubleshooting, “Engine speed/Timing sensor - Test”.
Ignition Key Switch Fault
Fault
5 Volt Sensor DC Power Supply Fault
8 Volt Sensor DC Power Supply
Customer/System Parmeter Fault
Fault
XX
XX
XX
XX X
X
i01902949
Fault Logging
The system provides the capability of Fault Logging. When the Electronic Control Module (ECM) generates an active diagnostic code, the code will be logged in the memory of the ECM. The codes that have been logged by the ECM can be identified by the electronic service tool. The active codes that have been logged will be cleared when the fault has been rectified or the fault is no longer active. The following logged faults can not be cleared from the memory of the ECM without using a factory password: Overspeed, low engine oil pressure, and high engine coolant temperature.
i02651197
Engine O peration with Active Diagnostic Codes
If a diagnostic lamp illuminates during normal engine operation, the system has identified a situation that is not within the specification. Use the electronic service tool to check the active diagnostic codes.
The active diagnostic code should be investigated. The cause of the problem should be corrected as soon as possible. If the cause of the active diagnostic code is repaired and there is only one active diagnostic code, the diagnostic lamp will turn off.
Operation of the engine and performance of the engine can be limited as a result of the active diagnostic code that is generated. Acceleration rates may be significantly slower and power outputs may be automatically reduced. Refer to Troubleshooting , “Troubleshooting with a Diagnostic Code” for more information on the relationship between each active diagnostic code and the possible effect on engine performance.
Page 37
SEBU8387 37
Operation Section
Engine Diagnostics
i01902995
Engine Operation with Intermittent
If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off, an intermittent occurred, the fault will be logged into the memory of the Electronic Control Module (ECM).
In most cases, it is not necessary to stop the engine because of an intermittent code. However, the operator sho and the operator should reference the appropriate information in order to identify the nature of the event. The operato have caused the lamp to light.
fault may have occurred. If a fault has
uld retrieve the logged fault codes
r should log any observation that could
Diagnostic Codes
Low power
•
Limits of the engine speed
•
Excessive smoke, etc
•
This inform the situation. The information can also be used for future reference. For more information on diagnostic codes, ref engine.
ation can be useful to help troubleshoot
er to the Troubleshooting Guide for this
Page 38
38 SEBU8387 Operation Section Engine Starting
Engine Starting
i02322201
Before Starting Engine
Before the en daily maintenance and any other periodic maintenance that is due. Refer to the Operation and Maintena Schedule” for more information.
Open the fuel
•
All valves in the fuel return line must be open before andduringen pressure. High fuel pressure may cause filter housing failure or other damage.
If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air may have ent filters have been changed, some air pockets will be trapped in the engine. In these instances, prime the fuel syste Manual, “Fuel System - Prime” for more information on priming the fuel system.
gine is started, perform the required
nce Manual, “Maintenance Interval
supply valve (if equipped).
NOTICE
gine operation to help prevent high fuel
ered the filter housing. Also, when fuel
m. Refer to the Operation and Maintenance
i02322203
Starting the Engine
Note: Do not adj
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 the
3. When the warning light for the glow plugs is extinguishe 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 engin
Do not engage the starting motor when flywheel is turning. Do
ust the engine speed control during
glow plugs is extinguished.
dturnthekeyswitchtotheSTART
e.
NOTICE
not start the engine under load.
Engine ex which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in outside.
Do not sta
•
if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the con
Reset all of the shutoffs or alarm components (if
•
equippe
Ensure that any equipment that is driven by the
•
engine h Minimize electrical loads or remove any electrical loads.
haust contains products of combustion
an enclosed area, vent the exhaust to the
rt the engine or move any of the controls
trols.
d).
as been disengaged from the engine.
If the engine fails to start within 30 seconds, release the starter allow the starting motor to cool before attempting to start the engine again.
4. Allow the keyswitch to return to the RUN position after the engine starts.
5. Repeat step 2 through step 4 if the engine fails to st art.
switch or button and wait two minutes to
i02325155
Cold Weather Starting
Do not use aerosol types of starting aids such as ether. Such use could result i n 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 39
SEBU8387 39
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 a start-up. The electronic control module (ECM) will control the engine speed during start-up.
1. Disengage any driven equipment.
2. Turn the keys
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 the st start the engine again.
sel fuel is used, the following items
et water heaters, fuel heaters, and fuel
dure that follows for cold weather
djust the engine speed control during
witch to the RUN position. Leave the
NOTICE
arting motor to cool before attempting to
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 engine.
Note: If it is possible, first diagnose the reason for
the starting failure. Refer to Troubleshooting, “Engine Will Not Crank and Engine Cranks But Will Not Start” for further information. Make any necessary repairs. If the engine will not start only due to the condition of the battery, either charge the battery, or start the engine by using another battery with jump start cables. The condition of the battery can be rechecked after the engine has been switched OFF.
3. When the war extinguished turn the keyswitch to the START position in order to engage the electric starting motor and c
Note: The operating period of the warning light for the glow pl of the engine.
4. Allow the k after the engine starts.
5. Repeat ste to start.
Note: The speed up the warm up process.
6. Allow the allow the engine to idle until the water temperature indicator begins to rise. When idling after the engine ha engine rpm from 1000 to 1200 rpm. This will warm up the engine more quickly. Maintaining an eleva will be easier with the installation of a hand throttle. Allow the white smoke to disperse before proceed
ning light for the glow plugs is
rank the engine.
ugs will change due to the temperature
eyswitch to return to the RUN position
p 2 through step 4 if the engine fails
engine should not be “raced” in order to
engine to idle for three to five minutes, or
s started in cold weather, increase the
ted low idle speed for extended periods
ing with normal operation.
NOTICE Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for jump starti the electrical system.
Do not reve be damaged. Attach ground cable last and remove first.
Turn all electrical accessories OFF before attaching the jump start cables.
Ensure that the main power switch is in the OFF posi­tion before attaching the jump start cables to the en­gine bein
1. Turn the start switch on the stalled engine to the
OFF posit
2. Connect one positive end of the jump start cable
to the pos battery. Connect the other positive end of the jump start cable to the positive cable terminal of the electri
ng. The use of higher voltage will damage
rse the battery cables. The alternator can
gstarted.
ion. Turn off all the engine’s accessories.
itive cable terminal of the discharged
cal source.
7. Operate the engine at low load until all systems reach op during the warm-up period.
erating temperature. Check the gauges
Page 40
40 SEBU8387 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 batte rie proper voltage with a battery charger after the engine is stopped. Many batteries which are considered unusable ar and Maintenance Manual, “Battery - Replace” and Testing and Adjusting Manual, “Battery - Test”.
s must be replaced or charged to the
e still rechargeable. Refer to Operation
ative end of the jump start cable
le to the engine block or to the
e produced by some batteries.
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 41
SEBU8387 41
Operation Section
Engine Operation
Engine Operation
i02330143
Engine Operation
Correct oper in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenance minimized and engine service life can be maximized.
The engine ca engine reaches operating temperature. The engine will reach normal operating temperature if the engine is operated light load. This procedure is more effective than idling the engine at no load. The engine should reach operating
Gauge readings should be observed and the data should be r is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing abnormal operating developments. Significant changes in the readings should be investigated.
ation and maintenance are key factors
Manual are followed, costs can be
n be operated at the rated rpm after the
at low idle speed and operated with a
temperature in a few minutes.
ecorded frequently while the engine
data over time will also help detect
i02330149
Fuel Conservation Prac tices
The efficiency o economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in all applicati in order to attain optimum performance for the life of the engine.
Avoid spilling fuel.
•
Fuel expands may overflow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed.
Be aware of the properties of the different fuels.
•
Use only the recommended fuels.
Avoid unnecessary idling.
•
Shut off the time.
Observe the
•
Keep the air cleaner elements clean.
Maintain th
•
f the engine can affect the fuel
ons. Follow the recommended procedures
when the fuel is warmed up. The fuel
engine rather than idle for long periods of
air cleaner service indicator frequently.
e electrical systems.
One damaged battery cell will overwork the alternator. This will co
Ensure that the drive belts are correctly adjusted.
•
The drive be
Ensure that all of the connections of the hoses are
•
tight. The
Ensure that the driven equipment is in good
•
working or
Cold engines consume excess fuel. Utilize heat
•
from the ja system, when possible. Keep cooling system components clean and keep cooling system component engine without water temperature regulators. All of these items will help maintain operating temperat
nsume excess power and excess fuel.
lts should be in good condition.
connections should not leak.
der.
cket water system and the exhaust
s in good repair. Never operate the
ures.
Page 42
42 SEBU8387 Operation Section Engine Stopping
Engine Stopping
i02334873
Stopping the Engine
NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and ac­celerated wear of the engine components.
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
Emergency
Stopping
i02330274
After Stopping Engine
Note: Before yo
the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan.
Contact with h penetration and burn hazards. High pressure fu­el spray may cause a fire hazard. Failure to fol­low these ins structions ma y cause personal injury or death.
After the eng
•
60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and f systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, “F
Check the crankcase oil level. Maintain the oil level
•
between th the engine oil level gauge.
If the engi
•
note the reading. Perform the maintenance that is in the Operation and Maintenance Manual, “Mainten
u check the engine oil, do not operate
igh pressure fuel may cause fluid
pection, maintenance and service in-
ine has stopped, you must wait for
or repair is performed on the engine
rom the cooling, lubrication or air
uel Injection Lines - Install”.
e “MIN” mark and the “MAX” mark on
ne is equipped with a service hour meter,
ance Interval Schedule”.
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
•
accumula the fuel tank.
Only use antifreeze/coolant mixtures recommended in the Coola 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.
Allow the engine to cool. Check the coolant level.
•
tion of moisture in the fuel. Do not overfill
NOTICE
nt Specifications that are in the Operation
Page 43
SEBU8387 43
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 44
44 SEBU8387 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 elec
•
fraying or damaged insulation.
Keep all batte
•
Fill the fuel tank at the end of each shift.
•
Check the air cleaners and the air intake daily.
•
Check the air intake more often when you operate in snow.
Ensure that the glow plugs are in working order.
•
Refer to Test
-Test”.
Personal injury or property damage can result from alcohol or starting fluids.
Alcohol or starting fluids are highly flammable and toxic and if improperly stored could result in injury or property
rect specification of engine lubricant
er parts (hoses, fan drive belts, etc)
trical wiring and connections for any
ries fully charged and warm.
ing and Adjusting Manual, “Glow Plug
damage.
The operation and maintenance of an engine in freezing temperatures is complex . This is because of the following conditions:
Weather conditions
•
Engine applications
•
Recommendations from your Perkins dealer or your Perkins distributor are based on past proven practices. The information that is contained in this section provides guidelines for cold weather operation.
Hints for Cold Weather Operation
If the engine will start, operate the engine until a
•
minimum operating temperature of 81 °C (177.8 °F) is achieved. Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking.
The cooling system and the lubrication system
•
for the engine do not lose heat immediately upon shutdown. This means that an engine can be shut downforaperiodoftimeandtheenginecanstill have the ability to start readily.
Do not use aerosol types of starting aids such as ether. Such use could result i n 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 45
SEBU8387 45
Operation Section
Cold Weather Operation
In cold weather correct glycol concentration in order to ensure adequate freeze protection.
, check the coolant often for the
Engine Block Heaters
Engine block h engine jacket water that surrounds the combustion chambers. This provides the following functions:
Startability is improved.
•
Warm up time i
•
An electric block heater can be activated once the engine is is typically a 1250/1500 W unit. Consult your Perkins dealer or your Perkins distributor for more information
Idling the E
When idling after the engine is started in cold weather, in rpm. This will warm up the engine more quickly. Maintaining an elevated low idle speed for extended periods wil throttle. The engine should not be “raced” in order to speed up the warm up process.
While the engine is idling, the application of a light load (parasitic load) will assist in achieving the minimum op operating temperature is 82 °C (179.6 °F).
eaters (if equipped) heat the
s reduced.
stopped. An effective block heater
.
ngine
crease the engine rpm from 1000 to 1200
l be easier with the installation of a hand
erating temperature. The minimum
Recommendations for Coolant Warm Up
Warm up an engine that has cooled below normal operatin be performed before the engine is returned to full operation. During operation in very cold temperature conditio result from engine operation for short intervals. This can happen if the engine is started and the engine is stopped to warm up completely.
When the temperatures, fuel and oil are not completely burned in the combustion chamber. This fuel and oil causes soft ca Generally, the deposits do not cause problems and the deposits are burned off during operation at normal
When the engine is started and the engine is stopped many ti up completely, the carbon deposits become thicker. This can cause the following problems:
g temperatures due to inactivity. This should
ns, damage to engine valve mechanisms can
many times without being operated in order
engine is operated below normal operating
rbon deposits to form on the valve stems.
engine operating temperatures.
mes without being operated in order to warm
Free operation
•
Valves become stuck.
•
Pushrods may become bent.
•
Other damage t
•
result.
For this reaso the engine must be operated until the coolant temperature is 71 °C (160 °F) minimum. Carbon deposits on t and the free operation of the valves and the valve components will be maintained.
In addition, the engine must be thoroughly warmed in order to keep other engine parts in better condition and the servi extended. Lubrication will be improved. There will be less acid and less sludge in the oil. This will provide longer serv rings, and other parts. However, limit unnecessary idle time to ten minutes in order to reduce wear and unnecessa
ry fuel consumption.
of the valves is prevented.
o valve train components can
n, when the engine is started,
he valve stems will be kept at a minimum
celifeoftheenginewillbegenerally
ice life for the engine bearings, the piston
The Water Temperature Regulator and Insulated
The engine is equipped with a water temperature regulator correct operating temperature jacket water circulates through the engine cylinder block and into the engine cy cylinder block via an internal passage that bypasses the valve of the coolant temperature regulator. This ensures t cold operating conditions. The water temperature regulator begins to open when the engine jacket water ha temperature. As the jacket water coolant temperature rises above the minimum operating temperature the water te more coolant through the radiator to dissipate excess heat.
The progressive opening of the water temperature regulator operates the progressive closing of the bypass head. This ensures maximum coolant flow to the radiator in order to achieve maximum heat
pation.
dissi
Note: Perkins discourages the use of all air flow
iction devices such as radiator shutters.
restr Restriction of the air flow can result in the following: high exhaust temperatures, power loss, excessive fan us
Heater Lines
. When the engine coolant is below the
linder head. The coolant then returns to the
hat coolant flows around the engine under
s reached the correct minimum operating
mperature regulator opens further allowing
passage between the cylinder block and
age, and reduction in fuel economy.
Page 46
46 SEBU8387 Operation Section Cold Weather Operation
A cab heater is b feed from the engine and the return lines from the cab should be insulated in order to reduce heat loss to the outside
eneficial in very cold weather. The
air.
Insulating the Air Inlet and Engine Compartment
When temperatures below −18 °C (−0°F)willbe frequently e is located in the engine compartment may be specified. An air cleaner that is located in the engine compartment into the air cleaner. Also, heat that is rejected by the engine helps to warm the intake air.
Additional heat can be retained around the engine by insulating the engine compartment.
ncountered, an air cleaner inlet that
may also minimize the entry of snow
i02685960
Fuel and the Effect from Cold Weather
Note: Only use grades of fuel that are recommended
by Perkins. Refer to this Operation and Maintenance Manual, “Flui
The following components provide a means of minimizing p
Glow plugs (if equipped)
•
Engine coolant heaters, which may be an OEM
•
option
Fuel heaters, which may be an OEM option
•
Fuel line ins
•
The cloud point is a temperature that allows wax crystals to f the fuel filters to plug.
d Recommendations”.
roblems in cold weather:
ulation, which may be an OEM option
orm in the fuel. These crystals can cause
The pour poin 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 temperatur that are fueled in one climate may not operate well if the engines are moved to another climate. Problems can result
Before troubleshooting for low power or for poor performan
Low temperature fuels may be available for engine operation fuels limit the formation of wax in the fuel at low temperatures.
For more information on cold weather operation, refer to the Operation and Maintenance Manual, “Cold Weather O Cold Weather”.
t is the temperature when diesel fuel
e for the engine’s application. Engines
due to changes in temperature.
ce in the winter, check the fuel for waxing.
at temperatures below 0 °C (32 °F). These
peration and Fuel Related Components in
Page 47
SEBU8387 47
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 pipe.
Some fuel tanks use supply lines that take fuel directly fro equipped with this system, regular maintenance of the fuel system filter is important.
m 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 intervals, prevent water and/or sediment from being pumped from the fuel storage tank and into the engine fuel tank.
Fuel Filte
A primary fuel filter is installed between the fuel tank and th the fuel filter, always prime the fuel system in order to remove air bubbles from the fuel system. Refer to the Ope Maintenance Section for more information on priming the fuel system.
The location of a primary fuel filter is important in cold weather operation. The primary fuel filter and the fuel supply li are affected by cold fuel.
and refueling of the fuel tank. This will help
rs
e engine fuel inlet. After you change
ration and Maintenance Manual in the
ne are the most common components that
Fuel Heaters
Note: Th
heaters. If this is the case, the temperature of the fuel must not exceed 73 °C (163 °F) at the fuel transfer pump.
e OEM may equip the application with fuel
For more information about fuel heaters (if equipped), refer to
the OEM information.
Page 48
48 SEBU8387 Maintenance Section Refill Capacities
Maintenance Section
Refill Capacities
i02237872
Refill Capacities
Lubrication System
The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter. Refer to the Operation and Maintenance Manual, “Maintenance Section” for more information on Lubricant Specifications.
Table 4
Engine
Refill Capacities
Compartment or System
Crankcase Oil Sump
(1)
These values are the approximate capacities for the crankcase oil sum p (aluminum) which includes the standard factory installed oil filters. Engines with auxiliary oil filters will require additional oil. Refer to the OE M specifications for the capacity of the auxiliary oil filter.
(1)
Minimum Maximum
13.5 L
(2.9696
Imp gal)
16.5 L
(3.6295
Imp gal)
i02761894
Fluid Recommendations
General Lubricant Info rm a tion
Because of gov certification of exhaust emissions from the engine, the lubricant recommendations must be followed.
EMA____________Engine Manufacturers Association
•
API_________
•
SAE___________________________________________ Society Of
•
Automotive En
EMA Guidelines
The “Engine Manufacturers Association Recommended Guideline on Diesel Engine Oil” is recognized b about this guideline, see the latest edition of EMA publication, “EMA DHD -1”.
API Licensing
The Engine Oi the American Petroleum Institute (API) is recognized by Perkins. For detailed information about this system, see No. 1509”. Engine oils that bear the API symbol are authorized by API.
ernment regulations regarding the
____________
American Petroleum Institute
gineers Inc.
y Perkins. For detailed information
l Licensing and Certification System by
the latest edition of the “API publication
Cooling System
Refer to the OEM specifications for the External System capacity. This capacity information will be needed in order to determine the amount of coolant/antifreeze that is required for the Total Cooling System.
Table 5
Engine
Refill Capacities
Compartment or System
Engine Only
External System Per OEM
(1)
The External System includes a r adiator or an expansion tank w ith the following components: heat ex changer and piping. Refer to the OEM specifications. Enter the value for the capacity of the External System in this row.
(1)
Liters
9 L (1.9797
Imp gal)
Illustration 26
Typical API symbol
g00546535
Page 49
SEBU8387 49
Maintenance Section
Refill Capacities
Termin olog y
Certain abbreviations follow the nomenclature of “SAE J754”. So
me classifications follow “SAE J183” abbreviations, and some classifications follow the “EMA Recommended Guideline on Diesel Engine Oil”. In addi
tion to Perkins definitions, there are other definitions that will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in this publi
cation, “Fluid Recommendations/Engine
Oil” topic (Maintenance Section).
Engine Oil
Commercial O
For applications above 168 kWCI-4 oil must be used.
Table 6
API Classifications for the 1106C Genset
Engine Power
Less than 168 kW (225 hp)
More than 168 kW (225 hp)
Less than 168 kW (225 hp)
Maintenance intervals for engines that use biodiesel – The oil change interval can be adversely
affected by the use of biodiesel. Use oil analysis in order to monitor the condition of the engine oil. Use oil analysis also in order to determine the oil change interval that is optimum.
Note: These engine oils are not approved by perkins and these engine oils must not be used:CC, CD , CD-2, and CF-4.
The performance of commercial diesel engine oils is based on API classifications. These API classifications are developed in order to provide commercial lubricants for a broad range of diesel engines that operate at various conditions.
Only use commercial oils that meet the following classifications:
ils
NOTICE
Oil Specification
CH-4/CI-4 500 Hours
CI-4
CG-4
Maintenance Interval
500 Hours
250 Hours
EMA DHD-1 – The E
MA has developed lubricant recommendations as an alternative to the API oil classification system. DHD-1 is a Recommended Guideline tha
tdefines a level of oil performance for these types of diesel engines: high speed, four stroke cycle, heavy-duty, and light duty. DHD-1 oils may be used in Per
kins engines when the following oils are recommended: API CH-4 and API CG-4. DHD-1 oils are intended to provide superior performance in comparison
to API CG-4.
DHD-1 oils will meet the needs of high performance Perkins die
sel engines that are operating in many applications. The tests and the test limits that are used to define DHD-1 are similar to the new API CH-4 classi
fication. Therefore, these oils will also meet the requirements for diesel engines that require low emissions. DHD-1 oils are designed to control the harmful ef
fects of soot with improved wear resistance and improved resistance to plugging of the oil filter. These oils will also provide superior piston deposit control f
or engines with either two-piece steel pistons
or aluminum pistons.
All DHD-1
oils must complete a full test program with the base stock and with the viscosity grade of the finishedcommercialoil.Theuseof“APIBase Oil Inter
change Guidelines” are not appropriate for DHD-1 oils. This feature reduces th e variation in performance that can occur when base stocks are changed
in commercial oil formulations.
DHD-1 oils are recommended for use in extended oil change i
nterval programs that optimize the life of the oil. These oil change interval programs are based on oil analysis. DHD-1 oils are recommended for
ions that demand a premium oil. Y our Perkins
condit 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
engines. Also, the oil was designed to
diesel meet the requirements of the low emissions diesel engines. API CH-4 oils are also acceptable for use
er diesel engines and in diesel engines that
in old use high sulfur diesel f uel. API CH-4 oils may be used in Perkins engines that use API CG-4 and API CF-4 o
ils. 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
ston rings, valve train wear, viscosity control,
of pi and corrosion.
API____________________________________________ CH-4 CI-4
•
In order to make the correct choice of a commercial oil, refer to the following explanations:
Page 50
50 SEBU8387 Maintenance Section Refill Capacities
Three new engin
e tests were developed for the API CH-4 oil. The firsttestspecifically evaluates deposits on pistons for engines with the two-piece steel piston. This test (pis
ton deposit) also measures the control of oil consumption. A second test is conducted with moderate oil soot. The second test measures the followin
g criteria: wear of piston rings, wear of cylinder liners, and resistance t o corrosion. A third new test measures the following characteristics with high levels
of soot in the oil: wear of the valve train, resistance of the oil in plugging the oil filter, and control of sludge.
In addition to the new tests, API CH-4 oils have tougher limits for viscosity control in applications that generate hi
gh soot. The oils also have improved oxidation resistance. API CH-4 oils must pass an additional test (piston deposit) for engines that use aluminum p
istons (single piece). Oil performance is also established for engines that operate in areas with high sulfur diesel fuel.
All of these improvements allow the API CH-4 oil to achieve optimum oil change intervals. API CH-4 oils are recom
mended for use in extended oil change intervals. API CH-4 oils are recommended for conditions that demand a premium oil. Your Perkins distribu
tor has specific guidelines for optimizing oil
change intervals.
Some comm
ercial oils that meet the API classifications may require reduced oil change intervals. To determine the oil change interval, closely monitor
the condition of the oil and perform a wear
metal analysis.
NOTICE
Failure
to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.
Total Ba
se Number (TBN) and Fuel Sulfur Levels for 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 dis must be 10 times the fuel sulfur level. The TBN is defined by “ASTM D2896”. The minimum TBN of the oil is demonstrates the TBN.
tillate fuel, the minimum TBN of the new oil
5 regardless of fuel sulfur level. Illustration 27
Illustration 27
(Y) TBN by “ASTM D2896” (X) Percentage of fuel sulfur by weight (1) TBN of new oil (2) Change the oil when the TBN deteriorates to 50 percent of
the original TBN.
g00799818
Use the following guidelines for fuel sulfur levels that exceed 1.5 percent:
Choose an oil with the highest TBN that meets one
•
of these classifications: EMA DHD-1 and API CH-4.
Reduce the oil change interval. Base the oil
•
change interval on the oil analysis. Ensure that the oil analysis includes the condition of the oil and a wear metal analysis.
Excessive piston deposits can be produced by an oil withahighTBN.Thesedepositscanleadtoaloss of control of the oil consumption and to the polishing of the cylinder bore.
NOTICE Operating Direct Injection (DI) diesel engines with fuel sulphur levels over 0.5 percent will require shortened oil change intervals in order to help maintain adequate wear protection.
Table 7
Percentage of Sulfur in the fuel
Lower than 0.5 Normal
0.5 to 1.0 0.75 of normal
Greater than 1.0 0.50 of normal
Oil change interval
Lubricant Viscosity Recommendations for D irect Injection (DI) Diesel Engines
The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation.
Page 51
SEBU8387 51
Maintenance Section
Refill Capacities
Refer to Table 8 determine the required oil viscosity for starting a cold engine.
Refer to Table 8 (maximum temperature) in order to select the oil viscosity f or engine operation at the highest ambi
Generally, use the highest oil viscosity that is available to at start-up.
Table 8
EMA LRG-1
API CH-4
Viscosity Grade
SAE 0W20 −40 °C (−40 °F) 10 °C (50 °F)
SAE 0W30 −40 °C (−40 °F) 30 °C (86 °F)
SAE 0W40 −40 °C (−40 °F) 40 °C (104 °F)
SAE 5W30 −30 °C (−22 °F) 30 °C (86 °F)
SAE 5W40 −30 °C (−22 °F) 40 °C (104 °F)
SAE 10W30 −20 °C (−4 °F) 40 °C (104 °F)
SAE 15W40 −10 °C (14 °F) 50 °C (122 °F)
(minimum temperature) in order to
ent temperature that is anticipated.
meet the requirement for the temperature
Engine Oil Viscosity
Ambient Temperature
Minimum Maximum
Synthetic Base Stock Oils
Synthetic base oils are acceptable for use in these engines if these oils meet the performance requirements that are specified for the engine.
Synthetic base oils generally perform better than conventional oils in the following two areas:
Synthetic base oils have improved flow at low
•
temperatures especially in arctic conditions.
Synthetic base oils have improved oxidation
•
stability especially at high operating temperatures.
Re-refined Base
Re-refined base stock oils are acceptable for use in Perkins performance requirements that are specified by Perkins. Re-refinedbasestockoilscanbeused exclusively base stock oils. The specification for the US military and the specifications of other heavy equipment manufacture stock oils that meet the same criteria.
The process t stock oil should adequately remove all wear metals that are in the used oil and all the additives that areintheus make re-refined base stock oil generally involves the process of vacuum distillation and hydrotreating the used oil. Fi high quality, re-refined base stock oil.
Lubricant
When an engine is started and an engine is operated in ambient multigrade oils that are capable of flowinginlow temperatures.
These oils have lubricant viscosity grades of SAE 0W or SAE 5W.
When an engine is started and operated in ambient temperatures below −30 °C (−22 °F), use a synthetic base stoc orwitha5Wviscositygrade.Useanoilwithapour point that is lower than −50 °C (−58 °F).
Perkins recommends the following lubricants for use in cold weather conditions:
Use a commercial oil tha t is API:CI-4, CI-4 PLUS, CH-4, and CG-4. The oil must have one of the followi 0W-30, SAE 0W-40, SAE 5W-30, and SAE 5W-40
in finished oil or in a combination with new
rs also allow the use of re-refined base
hatisusedtomakere-refined base
ed oil. The process that is used to
ltering is adequate for the production of
s for Cold Weather
temperatures below −20 °C (−4°F),use
k multigrade oil with an 0W viscosity grade
ng lubricant viscosity grades: SAE 0W-20, SAE
Stock Oils
engines if these oils meet the
Some synthetic base oils have performance characteristics that enhance the service life of the oil. Perkins does not recommend the automatic extending of the oil change intervals for any type of oil.
Afterma
Perkins does not recommend the use of aftermarket additiv additives in order to achieve the engine’s maximum service life or rated performance. Fully formulated, finishe additive packages. These additive packages are blended into the base oils at precise percentages in order t characteristics that meet industry standards.
rket Oil Additives
es in oil. It is not necessary to use aftermarket
d oils consist of base oils and of commercial
ohelpprovidefinished oils with performance
Page 52
52 SEBU8387 Maintenance Section Refill Capacities
There are no ind the performance or the compatibility of aftermarket additives in finished oil. Aftermarket additives may not be compati package, which could lower the performance of the finished oil. The aftermarket additive could fail to mix with the fi in the crankcase. Perkins discourages the use of aftermarket additives in finished oils.
To achieve the best performance from a Perkins engine, conform to the following guidelines:
Select the correct oil, or a commercial oil that meets
•
the “EMA Recommended Guideline on Diesel Engine Oil”
See the appropriate “Lubricant Viscosities” table in
•
order to find engine.
At the spec
•
new oil and install a new oil filter.
Perform ma
•
specified in the Operation and Maintenance Manual, “Maintenance Interval Schedule”.
ustry standard tests that evaluate
ble with the finished oil’s additive
nished oil. This could produce sludge
or the recommended API classification.
the correct oil viscosity grade for your
ified interval, service the engine. Use
intenance at the intervals that are
Oil analysis
Some engin valve. If oil analysis is required the oil sampling valve is used to obtain samples of the engine oil. The oil analysis w program.
The oil an determine oil performance and component wear rates. Contamination can be identified and measured through t includes the following tests:
The Wear
•
engine’s metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increas oil is as important as the quantity of engine wear metal in the oil.
Tests are conducted in order to detect
•
contamination of the oil by water, glycol or fuel.
The Oil Condition Analysis determines the loss of
•
the oil’s lubricating properties. An infrared analysis is used properties of the used oil sample. This analysis allows technicians to determine the amount of deteri also allows technicians to verify the performance oftheoilaccordingtothespecification during the entir
es may be equipped with an oil sampling
ill complement the preventive maintenance
alysis is a diagnostic tool that is used to
he use of the oil analysis. The oil analysis
Rate Analysis monitors the wear of the
e in the rate of engine wear metal in the
to compare the properties of new oil to the
oration of the oil during use. This analysis
e oil change interval.
Page 53
SEBU8387 53
Maintenance Section
Maintenance Interval Schedule
i02761000
Maintenance Interval Schedule
When Required
Battery - Replace .................................................. 56
Battery or Battery Cable - Disconnect .................. 57
Engine - Clean ...................................................... 6
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 64
Engine Air Clea
Inspect/Replace .................................................. 66
Engine Oil Sample - Obtain .................................. 68
Fuel System - Pr
Severe Service Application - Check ..................... 83
Daily
Cooling System Coolant Level - Check ................ 60
Driven Equipment - Check .................................... 63
Engine Air Clea
Engine Air Precleaner - Check/Clean ................... 67
Engine Oil Level - Check ...................................... 67
Fuel System Prim
Drain ................................................................... 74
Walk-Around Inspection ........................................ 85
ner Element (Single Element) -
ime ............................................. 72
ner Service Indicator - Inspect ..... 66
ary Filter/Water Separator -
Every 1000 Serv
Engine Valve Lash - Inspect/Adjust ...................... 70
Water Pump - Ins
ice Hours
pect ........................................... 86
Every 2000 Service Hours
Aftercooler C
Alternator - Inspect ............................................... 55
Engine Mounts - Inspect ....................................... 67
3
Starting Motor
Turbocharger - Inspect .......................................... 84
ore - Inspect ..................................... 54
- Inspect ........................................ 84
Every 3000 Service Hours
Alternator and Fan Belts - Replace ....................... 55
Every 3000 Service Hours or 2 Years
Cooling System Coolant (Commercial Heavy-Duty) -
Change ............................................................... 57
Every 4000 Serv
Aftercooler Core - Clean/Test ............................... 54
Every 12 000 Ser
Cooling System Coolant (ELC) - Change ............. 59
ice Hours
vice Hours or 6 Years
Every Week
Alternator and Fan Belts - Inspect ........................ 55
Hoses and Clamps
- Inspect/Replace .................. 81
Every 50 Service Hours or Weekly
Fuel Tank Water a
nd Sediment - Drain ................. 81
Initial 500 Service Hours
Engine Valve Las
h - Inspect/Adjust ...................... 70
Every 500 Service Hours
Fan Clearance - C
heck ......................................... 71
Every 500 Service Hours or 1 Year
Battery Electro Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 62
Crankcase Breat Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 64
Engine Air Clean
Inspect/Replace .................................................. 66
Engine Oil and Filter - Change ............................. 68
Fuel System Prim
Element - Replace .............................................. 75
Fuel System Secondary Filter - Replace .............. 79
Radiator - Clean
lyte Level - Check .......................... 56
her (Canister) - Replace ............. 62
er Element (Single Element) -
ary Filter (Water Separator)
.................................................... 82
Commissioning
Fan Clearance - Check ......................................... 71
Page 54
54 SEBU8387 Maintenance Section Aftercooler Core - Clean/Test
i02322260
Aftercooler Co r e - Clean/Test
1. Remove the core
for the correct procedure.
2. Turn the afte r
remove debris.
Personal injury can result from air pressure.
Personal inju er procedure. When using pressure air, wear a pro­tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.
3. Pressurized air is the preferred method for
removing loose debris. Direct the air in the opposite dir nozzle approximately 6 mm (.25 inch) away from the fins. Slowly move the air nozzle in a direction that is para debris that is between the tubes.
. Refer to the OEM information
cooler core upside-down in order to
ry can result without following prop-
ection of the fan’s air flow. Hold the
llel with the tubes. This will remove
Personal injury can result from air pressure.
Personal injury can result without following prop­er procedure. When using pressure air, wear a pro­tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.
8. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
9. Inspect the core in order to ensure cleanliness. Pressure test the core. If necessary, repair the core.
10. Install the core. Refer to the OEM information for the correct procedure.
11. After cleaning, start the engine and accelerate theenginetohighidlerpm.Thiswillhelpinthe removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.
i02322295
4. Pressurize The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressuriz thecorefrombothsides.
Do not use a high concentration of caustic cleaner to clean the c can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner.
5. Back flush the core with a suitable cleaner.
6. Steam clea
residue. Flush the fins of the aftercooler core. Remove any other trapped debris.
7. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.
d water may also be used for cleaning.
ed water in order to soften mud. Clean
NOTICE
ore. A high concentration of caustic cleaner
n the core in order to remove any
Aftercooler Core - Inspect
Note: Adju
the effects of the operating environment.
Inspect th corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the aftercooler, if necessary.
For air-to-air aftercoolers, use the same methods that are used for cleaning radiators.
Personal
Personal injury can result without following prop­er proced tective face shield and protective clothing.
Maximum a than 205 kPa (30 psi) for cleaning purposes.
st the frequency of cleaning according to
e aftercooler for these items: damaged fins,
injury can result from air pressure.
ure. When using pressure air, wear a pro-
ir pressure at the nozzle must be less
Page 55
SEBU8387 55
Maintenance Section
Alternator - Inspect
After cleaning engine to high idle rpm. This will help in the removal of debris and drying of the core. Stop the engine. Use a light bul the core for cleanliness. Repeat the cleaning, if necessary.
Inspect the fins for damage. Bent fins may be opened with a “comb”.
Note: If parts of the aftercooler system are repaired or replaced, a leak test is highly recommended.
Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps, and seals. Ma
, start the engine and accelerate the
b behind the core in order to inspect
ke repairs, if necessary.
i02322311
Alternator - Inspect
Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and correct battery charging. Check the ammeter (if equipped) during engine operation in order to ensure correct battery performance and/or correct performance of the electrical system. Make repairs, as required.
If the belt (1) h
•
25.4000 mm (1 inch) the belt must be replaced.
Check the belt
•
and splitting.
as more than four cracks per
for cracks, splits, glazing, grease,
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.
i02680086
Altern Inspect
Ensure that the engine is stopped before any servicing or repair is performed.
To maximize the engine performance, inspect the belt (1) for wear and for cracking. Replace the belt if the belt is worn or damaged.
ator and Fan Belts -
NOTICE
Illustration 28
Typical e
xample
Alternat
or and Fan Belts -
g01347573
i02680137
Replace
Refer to Disassembly and Assembly Manual , “ Alterna
tor Belt - Remove and Install”.
Page 56
56 SEBU8387 Maintenance Section Battery - Replace
i02322315
Battery - Replace
Batteries give off combustible gases which can explode. A spark can cause the combustible gas­es to ignite. T jury or death.
Ensure prope an enclosure. Follow the proper procedures in or­der to help prevent electrical arcs and/or sparks near batteri serviced.
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.
his can result in severe personal in-
r ventilation for batteries that are in
es. Do not smoke when batteries are
8. Connect the NEG
“-” battery terminal.
ATIVE “-” cable to the NEGATIVE
i02747977
Battery E lectrolyte Level ­Check
When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries are correctly charged, the ammeter reading should be very near zero, when the engine is in operation.
All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing whe n 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.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that
the engine start switch is OFF.
7. Connect the cable from the starting motor to the POSITIVE “+” battery terminal.
Page 57
SEBU8387 57
Maintenance Section
Battery or Battery Cable - Disconnect
i02323088
Battery or Battery Cable ­Disconnect
The battery cables or the batteries should not be removed with tery cover should be removed before any servic­ing is attempted.
Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in
1. Turn the start switch to the OFF position. Turn the
ignition sw and remove the key and all electrical loads.
2. Disconnect that the cable cannot contact the terminal. When four 12 volt batteries are involved, two negative connection
3. Remove the positive connection.
4. Clean all disconnected connection and battery
terminals.
the battery cover in place. The bat-
personal injury.
itch (if equipped) to the OFF position
the negative battery terminal. Ensure
must be disconnected.
i02238072
Cooling System Coolant (Commercial H
eavy-Duty) -
Change
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test­ing, 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 part
Contaminants may cause rapid wear and shortened component li
Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist:
The engine overheats frequently.
•
s clean from contaminants.
fe.
5. Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the s remove material excessively. Excessive removal ofmaterialcancausetheclampstonotfit correctly a suitable silicone lubricant or petroleum jelly.
6. Ta pe th e c prevent accidental starting.
7. Proceed w
8. In order to connect the battery, connect the
positive
urfaces a re bright or shiny. DO NOT
. Coat the clamps and the terminals with
able connections in order to help
ith necessary system repairs.
connection before the negative connector.
Foaming 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
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.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.
Page 58
58 SEBU8387 Maintenance Section Cooling System Coolant (Commercial Heavy-Duty) - Change
Illustration 29
Typical exam ple
g01144180
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 dealer or your Perkins distributor.
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
4. Start and run th
e engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
5. Stop the engin
e and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler
cap. Open the drain cock or remove the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the water to d
rain. Flush the cooling system with
clean water.
Fill
1. Close the dra
engine. Close the drain cock or install the drain plug on the radiator.
Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine damage.
2. Fill the coo Heavy-Duty Coolant. Add Supplemental Coolant Additive to the coolant. For the correct amount, refer to the “Fluid Recommendations” topic (Maintenance Section) for more information on cooling system specificat filler cap.
3. Start and r engine rpm to high idle. Run the engine at high idle for one minute in order to purge the air from the cavit engine speed to low idle. Stop the engine.
4. Check the within 13 mm (0.5 inch) below the bottom of the pipe for filling. Maintain the coolant level in the expansio
in cock or install the drain plug on the
NOTICE
ling system with Commercial
Operation and Maintenance Manual,
ions. Do not install the cooling system
un the engine at low idle. Increase the
ies of the engine block. Decrease the
coolant level. Maintain the coolant level
n bottle (if equipped) at the correct level.
2. Close the drain cock or install the drain plug in the engine. Close the drain cock or install the drain plug on the radiator.
NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine damage.
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
Illustration 30
Filler cap
g00103639
Page 59
SEBU8387 59
Maintenance Section
Cooling System Coolant (ELC) - Change
5. 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 filler cap. If the filler cap install a new filler cap.
6. Start the eng
leaks and for correct operating temperature.
ng system filler cap and inspect the
,useasuitablepressurizingpump
does not retain the correct pressure,
ine. Inspect the cooling system for
i02238084
Cooling Sy stem Coolant (ELC)
- Change
NOTICE Care must be taken to ensure that fluids are contained during perf ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open­ing any com nent containing fluids.
ormance of inspection, maintenance, test-
partment or disassembling any compo-
Drain
Pressurized Sy ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components ar pressure cap slowly in order to relieve the pres­sure.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in order to reli system filler cap.
stem: Hot coolant can cause seri-
e cool. Loosen the cooling system
eve any pressure. Remove the cooling
Dispose of mandates.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Clean the cooling system and flush the cooling system bef interval if the following conditions exist:
The engine
•
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 when the ELC is drained and replaced
Note: Inspect the water pump and the water temperat been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hose
all fluids according to Local regulations and
NOTICE
ore the recommended maintenance
overheats frequently.
.
ure regulator after the cooling system has
s, if necessary.
Illustration 31
Typical example
2. Open the drain cock or remove the drain p lug (1) on the engine. Open the drain cock or remove the drain plug on the radiator.
Allow the coolant to drain.
NOTICE Dispose of used engine coolant or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Perkins to reclaim the coolant.
For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor.
g01144180
Page 60
60 SEBU8387 Maintenance Section Cooling System Coolant Level - Check
Flush
1. Flush the cooli
to remove any debris.
2. Close the drain 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.
3. Fill the cooli 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 filler the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the water to clean water.
ng system with clean water in order
cock or install the drain plug in the
NOTICE
ng system with clean water. Install the
he engine at low idle until the
ne and allow the engine to cool.
cap. Open the drain cock or remove
drain. Flush the cooling system with
Fill
1. Close the dr
engine. Close the drain cock or install the drain plug on the radiator.
ain cock or install the drain plug on the
Illustration 32
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 t emperature.
g00103639
i02335378
Cooling System Coolant Level
- Check
NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine damage.
2. Fill the co
Coolant (ELC). Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Mai 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 o 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 expansion bottle (if equipped) at the correct level.
oling system with Extended Life
ntenance Section) for more information
ne minute in order to purge the air from
filling. Maintain the coolant level in the
Engines With a Coolant Recovery Tank
Note: The cooling system may not have been
provided is for typical cooling systems. Refer to the OEM information for the correct procedures.
Check the coolant level when the engine is stopped and cool.
1. Observe the coolant level in the coolant recovery
by Perkins. The procedure that follows
tank. Maintain the coolant level to “COLD FULL” mark on t
he coolant recovery tank.
Page 61
SEBU8387 61
Maintenance Section
Cooling System Coolant Level - Check
Pressurized System: Hot coolant can cause seri­ous burns. To open t he cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loose n the cooling system pressure cap slowly in order to reliev e the pres­sure.
2. Loosen filler cap slowly in order to relieve any
pressure. Remove the filler cap.
3. Pour the correct coolant mixture into the tank.
Refer to the Operation and Maintenance Manual, “Refill Capacities and Recommendations” for information on the correct mixture and type of
Illustration 34
Cooling system filler cap
g00285520
coolant. Refer to the Operation and Maintenance Manual, “Refill Capacities and Recommendations” for the cooling system capacity. Do not fill the coolant recovery tank above “COLD FULL” mark.
Pressurized System: Hot coolant can cause seri­ous burns. To open the cooling system filler cap, stop the eng
ine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pres­sure.
Illustra
tion 33
g00103639
4. Clean filler cap and the receptacle. Reinstall the filler cap
and inspect the cooling system for leaks.
Note: The coolant will expand as the coolant heats up during
normal engine operation. The additional volume will be forced into the coolant recovery tank during engine operation. When the engine is stopped and cool
Engines
, the coolant will return to the engine.
Without a Coolant
Recovery Tank
Check the coolant level when the engine is stopped and cool.
1. Remove the cooling system filler cap slowly in order to rel
ieve pressure.
2. Maintain the coolant level within 13 mm (0.5 inch) of the bott
om of the filler pipe. If the engine is equipped with a sight glass, maintain the coolant level to the correct level in the sight glass.
3. Clean the cooling system filler cap and inspect the gasket. If the gasket is damaged, discard the old filler cap
and install a new filler cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the filler cap. The correct pressure
isstampedonthefaceofthefiller cap. If the filler cap does not retain the correct pressure, install a new filler cap.
4. Inspect the cooling system for leaks.
Page 62
62 SEBU8387 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add
i02335389
Cooling System Supplemental Coolant Addit
ive (SCA) -
Test/Add
Cooling system coolant additive contains alkali. To help prevent personal injury, avoid contact with the skin and the eyes. Do not drink cooling system coolant additive.
Test for SCA Concentration
Heavy-Duty Coolant/Antifreeze and SCA
NOTICE Do not exceed mental coolant additive concentration.
Use a Coolant Conditioner Test Kit in order to check the concentr
Add the SCA, I
Do not exceed the recommended amount of sup­plemental c supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling sys characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temper­ature comp additive concentration could also result in radiator tube blockage, overheating, and/or accelerated water pump seal w coolant additive and the spin-on element (if equipped) at the same time. The use of those additives together could res tration exceeding the recommended maximum.
the recommended six percent supple-
ation of the SCA.
f Necessary
NOTICE
oolant additive concentration. Excessive
tem, reducing the engine’s heat transfer
onents. Excessive supplemental coolant
ear. Never use both liquid supplemental
ult in supplemental coolant additive concen-
1. Slowly loosen t 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
3. AddthecorrectamountofSCA.Refertothe Operation an Capacities and Recommendations” for more information on SCA requirements.
4. Clean the cooling system filler cap and inspect the gasket. If the gasket is damaged, discard the old filler cap an is not damaged, use a suitable pressurizing pump in order to pressure test the filler cap. The correct pressure i the filler cap does not retain the correct pressure, install a new filler cap.
he cooling system filler cap in
extra SCA.
d Maintenance Manual, “Refill
dinstallanewfiller cap. If the gasket
s stamped on the face of the filler cap. If
i02667594
Crankcase Breather (Canister)
- Replace
NOTICE Ensure that the engine is stopped before any servicing or repair
1. Place a container under canister (2).
2. Clean the outside of the canister. Use a suitable
is performed.
tool in order to remove the canister.
Pressurized System: Hot coolant can cause seri­ous burns. To open t he cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loose n the cooling system pressure cap slowly in order to reliev e the pres­sure.
Page 63
SEBU8387 63
Maintenance Section
Driven Equipment - Check
i01909392
Engine - C lean
Personal injury or death can result from high v olt­age.
Moisture can create paths of electrical conductiv­ity.
Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls “DO NOT OPERATE”
Accumulatedgreaseandoilonanengineisafire haz­ard. Keep the engine clean. Remove debris and fluid spills whenever a significant quantity accumulates on the engine.
.
NOTICE
Illustration 35
Typical ex
3. Lubricate O ring seal (1) on the new canister with
4. Install the new canister. Spin on the canister until
5. Remove th
ample
clean eng
the O ring Then rotate the canister ¾ of a full turn.
and any split oil in a safe place.
ine lubricating oil.
seal contacts the sealing surface (3).
e container. Dispose of the old canister
g01340520
i02151646
Driven Equipment - Check
Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment:
Inspection
•
NOTICE Failure to protect some engine components from washing may make your engine warranty invalid. Allow the eng the engine.
Periodic cle 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: Caution must be used in order to prevent electrical excessive water when the engine is cleaned. Pressure washers and steam cleaners should not be directed at 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.
inetocoolforonehourbeforewashing
aning of the engine is recommended.
tenance
components from being damaged by
any electrical connectors or the junction of
otect the fuel injection pump from fluids
Adjustment
•
Lubrication
•
Other maintenance recommendations
•
Perform any maintenance for the driven equipment which is recommended by the OEM.
Page 64
64 SEBU8387 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace
i02334355
Engine Air C lean er Element (Dual Element
Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent air­borne debris from entering the air inlet.
Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements
Note: The air filter system may not have been
provided by Perkins. The procedure that follows is for a typic information for the correct procedure.
If the air cle can split the material of the air cleaner element. Unfiltered air will drastically accelerate internal engine wear correct air cleaner elements for your application.
Check the pr
•
bowl daily for accumulation of dirt and debris. Remove any dirt and debris, as needed.
Operating in dirty conditions may require more
•
frequent service of the air cleaner element.
The air cleaner element should be replaced at least
•
one time per year. This replacement should be performed
Replace the dirty air cleaner elements with clean air cleaner el elements should be thoroughly checked for tears and/or holes in the filter material. Inspect the gasket or the sea Maintain a supply of suitable air cleaner elements for replacement purposes.
al air filter system. Refer to the OEM
aner element becomes plugged, the air
. Refer to the OEM information for the
ecleaner (if equipped) and the dust
regardless of the number of cleanings.
ements. Before installation, the air cleaner
l of the air cleaner element for damage.
) - Clean/Replace
NOTICE
NOTICE
The primary air to six times if the element is properly cleaned and properly inspected. The primary air cleaner element should be repl replacement should be performed regardless of the number of cleanings.
The secondary air cleaner element is not serviceable. Refer to the OEM information for instructions in order to replace th
When the engine is operating in environments that are dusty or d more frequent replacement.
Illustration 36
(1) Cover (2) Primary air cleaner element (3) Secondary air cleaner element (4) A ir inlet
1. Remove the
cleaner element.
2. The second
removed and discarded for every three cleanings of the primary air cleaner element.
Note: Refer to “Cleaning the Primary Air Cleaner Elements”.
3. Cover the air inlet with tape in order to keep dirt
out.
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
5. Remove the tapefrom the air inlet. Install the
secondary air cleaner element. Install a primary air clean
cleaner element can be used up
aced at least one time per year. This
e secondary air cleaner element.
irty, air cleaner elements may require
g0073643
cover. Remove the primary air
ary air cleaner element should be
er element that is new or cleaned.
1
Dual Element Air Cleaners
The dual e cleaner element and a secondary air cleaner element.
lement air cleaner contains a primary air
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.
Page 65
SEBU8387 65
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Cleaning the Primary Air Cleaner Elements
Refer to the OEM information in order to determine the number of times that the primary filter element can be cleaned. When the primary air cleaner element is cleaned, check for rips or tears in the filter material. The primary air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.
NOTICE
Do not tap or strike the air cleaner element.
Do not wash the primary air cleaner element.
Use low pressure (207 kPa; 30 psi maximum) pres­surised air or vacuum cleaning to clean the primary air cleaner element.
Take extreme care in order to avoid damage to the air cleaner elements.
Do not use air cleaner elements that have damaged pleats, gaskets or seals.
Pressurized Ai
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.
r
Refer to the OEM information in order to determine the number of times that the primary air cleaner element can be cleaned. Do not clean the primary air filter element more than three times. The primary air cleaner element must be replaced at least one time per year.
Cleaning the air filter element will not extend the life of the air filter element.
Visually inspect the primary air cleaner element before cleaning. Inspect air cleaner elements for damage to the pleats, the seals, the gaskets and the outer cover. Discard any damaged air cleaner element.
Two methods may be used in order to clean the primary air cleaner element:
pressurized air
•
Vacuum cleaning
•
Illustration 37
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
Vacuum Cleaning
Vacuum cleaning is a good method for removing accumulated dirt from the dirty side (outside) of a primary air cleaner element. Vacuum cleaning is especially useful for cleaning primary air cleaner elements which require daily cleaning because of a dry, dusty environment.
Cleaning from the clean side (inside) with pressurized air is recommended prior to vacuum cleaning the dirty side (outside) of a primary air cleaner element.
Page 66
66 SEBU8387 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace
Note: Refer to “ Elements”.
Inspecting th
Inspecting the Primary Air Cleaner
e Primary Air Cleaner
Elements
Illustration 38
Inspect the Usea60wattbluelightinadarkroomorinasimilar facility. Place the blue light in the primary air cleaner element. Ro Inspect the primary air cleaner element for tears and/or holes. Inspect the primary air cleaner element for light t is necessary in order to confirm the result, compare the primary air cleaner element to a new primary air cleaner el
Do not use a primary air cleaner element that has any tears use a primary air cleaner element with damaged pleats, gaskets or seals. Discard damaged primary air clean
clean, dry primary air cleaner element.
tate the primary air cleaner element.
hat may show through the fi lter material. If it
ement that has the same part number.
and/or holes in the filter material. Do not
er elements.
g00281693
NOTICE Never service t running since this will allow dirt to enter the engine.
A wide variety o with this engine. Consult the OEM information for the correct procedure to replace the air cleaner.
he air cleaner element with the engine
f air cleaners may be installed for use
i02335405
Engine Air Cleaner Service Indicator - Inspect
Some engines service indicator.
Some engines for inlet air pressure. The differential gauge for inlet air pressure displays the difference in the pressure that is meas the pressure that is measured after the air cleaner element. As the air cleaner element becomes dirty, the pressur equipped with a different type of service indicator, follow the OEM recommendations in order to service the air cle
The service indicator may be mounted on the air cleaner el
may be equipped with a different
are equipped with a differential gauge
ured before the air cleaner element and
e differential rises. If your engine is
aner service indicator.
ement or in a remote location.
i02152042
Engine Ai
r Cle aner Element (Single Element) ­Inspect/Replace
Refer to Air Cleaner Service Indicator-Inspect”.
Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent air­borne debris from entering the air inlet.
Operation and Maintenance Manual, “Engine
NOTICE
Illustration 39
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
Page 67
SEBU8387 67
Maintenance Section
Engine Air Precleaner - Check/Clean
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.
If the service indicator does not reset easily, or if the yellow core does not latch at the greatest vacuum, the service indicator should be replaced. If the new service indicator will not reset, the hole for the service indicator may be restricted.
The service indicator may need to be replaced frequently in environments that are severely dusty.
i02343354
Engine Air Precleaner ­Check/Clean
i02323089
Engine Mounts - Inspect
Note: The engin
supplied by Perkins. Refer to the OEM information for further information on the engine mounts and the correct bolt t
Inspect the engine mounts for deterioration and for correctboltt by the following conditions:
Incorrect mo
•
Deterioration of the engine mounts
•
Loose engine mounts
•
Any engine mo be replaced. Refer to the OEM information for the recommended torques.
e mounts may not have been
orque.
orque. Engine vibration can be caused
unting of the engine
unt that shows deterioration should
i02335785
Illustration 40
Typical exam ple
(1) Wing n (2) Cov er (3) B ody
ut
g002870
Remove wing nut (1) and cover (2). Check for an accumula
tion of dirt and debris in body (3). Clean the
body, if necessary.
After cle
aning the precleaner, install cover (2) and
wing nut (1).
Engine Oil Level - C heck
Hot oil and h injury. Do not allow hot oil or hot components to contact the skin.
39
Illustration 41
(Y) “Min” mark. (X) “Max” mark.
ot components can cause personal
g0116583
6
Note: Whe
n the engine is operated in dusty
applications, more frequent cleaning is required.
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.
Page 68
68 SEBU8387 Maintenance Section Engine Oil Sample - Obtain
Note: After the 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 (X).
Operating you “FULL” mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into acteristics and could result in the loss of power.
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
engine has been switched OFF , wait
crankcase above the “FULL” mark
NOTICE
r engine when the oil level is above the
the 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.
Engine number
•
Service hours on the engine
•
The number of hours that have accumulated since
•
the last oil change
The amount of oil that has been added since the
•
last oil change
Ensure that the container for the sample is clean and dry. Also ensure that the container for the sample is clearly labe
To ensure that the sample is representative of the oil in the cra sample.
To avoid cont and the supplies that are used for obtaining oil samples must be clean.
The sample can be checked for the following: the quality of the oil, the existence of any coolant in the oil, the exi the oil, and the existence of any nonferrous metal particles in the oil.
lled.
nkcase, obtain a warm, well mixed oil
amination of the oil samples, the tools
stence of any ferrous metal particles in
i02667766
Engine Oil and Filter - Change
Perkins recommends using a sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when a sampling valve is used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation.
Obtain the Sample and the Analysis
Hot oil and hot components c an cause personal injury. Do not allow hot oil or hot components to contact the skin.
In order to help obtain the most accurate analysis, record the following information before an oil sample is taken:
Thedateofthesample
•
Engine model
•
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
NOTICE Care must b during performance of inspection, maintenance, test­ing, adjusting and repair of the product. Be prepared to collect th ing any compartment or disassembling any compo­nent containing fluids.
Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
e taken to ensure that fluids are contained
e fluid with suitable containers before open-
NOTICE
Page 69
SEBU8387 69
Maintenance Section
Engine Oil and Filter - Change
Do not drain the
engine lubricating oil when the engine is cold. As the engine lubricating oil cools, suspended waste particles settle on the bottom of the oil pan. Th
e waste particles are not removed with draining cold oil. Drain the oil pan with the engine stopped. Drain the oil pan with the oil warm. This draining met
hod allows the waste particles that are
suspended in the oil to be drained properly.
Failuretofo
llow this recommended procedure will cause the waste particles to be recirculated through theenginelubricationsystemwiththenewoil.
Drain the Engine Lubricating Oil
Note: Ensure that the vessel that will be used is large
enough to collect the waste oil.
After the engine has been run at the normal operating temperature, stop the engine. Use one of the following m
ethods to drain the engine oil pan:
Replace the Oil Filter
NOTICE Perkins oil fil fications.Useofanoilfilter that is not recommended by Perkins could result in severe damage to the en­gine bearing waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by Perkins.
1. Remove the oil filter with a suitable tool.
Note: The following actions can be carried out as
part of the preventive maintenance program.
2. Cut the oil filter open with a suitable tool. Break
apart the pleats and inspect the oil filter for metal debris. An e the oil filter may indicate early wear or a pending failure.
Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filt wear on the steel and cast iron parts of the engine.
ters are manufactured to Perkins speci-
s, crankshaft, etc., as a result of the larger
xcessive amount of metal debris in
er element. Ferrous metals may indicate
Illustration 42
Typical exam ple
If the engine is equipped with a drain valve, turn the
•
g01333817
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.
Nonferrou
s metals may indicate wear on the aluminum parts, brass parts or bronze parts of the engine. Parts that may be affected include the following
items: main bearings, rod bearings, and
turbocharger bearings.
Due to nor
mal wear and friction, it is not uncommon to find small amounts of debris in the oil filter.
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).
Illustration 43
Typical example
g01333549
Page 70
70 SEBU8387 Maintenance Section Engine Valve Lash - Inspect/Adjust
3. Clean sealing s
urface (2).
4. Apply clean engine oil to O ring seal (3) for the new oil filter.
NOTICE Do not fill the oil filters with oil before installing them. This oil would not be filtered and could be contaminat­ed. Contamina
ted oil can cause accelerated wear to
engine components.
5. Install the ne
woilfilter. Spin on the oil filter until the O ring contacts the sealing surface (2). Then rotate the oil filter ¾ of a full turn.
Note: Some oil filters may be installed horizontally. Refer to illustration 44. This type of oil filter assembly canbedraine
d before the filter is removed. The torque for this drain plug (4) is 12 N·m (8 lb ft). If necessary, install a new O ring seal (5). Start at step 1 in order to r
emove the oil filter and install the oil filter.
NOTICE
If equipped wit
hanauxilliaryoilfilter system or a re­mote filter system, follow the OEM or the filter manu­facture’s remonmendations. Under filling or over filling the crankcase
with oil can cause engine damage.
2. Start the engine and run the engine at “LOW
IDLE” for two m
inutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled. Inspect the oil filter for oil
leaks.
3. Stop the engine and allow the oil to drain back to the oil pan fo
r a minimum of ten minutes.
Illustration 44
Typical exam ple
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.
g01169166
Illustration 45
(Y) “Min” m
ark. (X) “Ma x” mark.
g01165836
4. Remove the engine oil level gauge in order to check the o
il level. Maintain the oil level between the “MIN” and “MAX” marks on the engine oil level gauge.
i02348484
Engine Valve Lash ­Inspect/Adjust
This maintenance is recommended by Perkins as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life.
NOTICE Only qualified service personel should perform this maintenance. Refer to the Service Manual or your au­thorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure.
Operation of Perkins engines with incorrect valve lash can reduce engine efficiency, and also reduce engine component life.
Page 71
SEBU8387 71
Maintenance Section
Fan Clearance - Check
Ensure that the engine can not be started while this maintenance is being performed. To help pre­vent possible injury, do not use the starting motor to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the engine to cool before mea­suring/adjusting valve lash clearance.
Ensure that the engine is stopped before measuring the valve lash. The engine valve lash can be inspected and adjusted when the temperature of the engine is hot or cold.
Refer to Systems Operation/Testing and Adjusting, “Engine Valve Lash - Inspect/Adjust” for more information.
i02683336
Fan Clearance - Ch eck
There are different types of cooling systems. Refer to the OEM for information on clearance for the fan.
Ensure that the engine is stopped. Ensure that the cooling system is full. The clearance between the cover (1) and the fan (2) will require checking. The gap (A) between the edge of the cover and the tip of the fan blade must be checked in four equally spaced positions.
Page 72
72 SEBU8387 Maintenance Section Fuel System - Prime
Illustration 4 6
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).
i02668315
Fuel System - Prime
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.
g01348394
Refer to the Operation and Maintenance Manual , “General Hazard Information and High Pressure Fuel Lines” before adjustments and repairs are performed.
Note: Refer to Testing and Adjusting Manual , “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training.
NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
If air enters the fuel system, the air must be purged from the fuel system before the engine can be started. Air can enter the fuel system when the following events occur:
Page 73
SEBU8387 73
Maintenance Section
Fuel System - Prime
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 follow from the fuel system:
1. Ensure that th Check that the fuel supply valve (if equipped) is in the “ON” position.
ing procedures in order to remove air
e fuel system is in working order.
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, ma intenance and service in­structions ma y cause personal injury or death.
After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, “Fuel Injection Lines - Install”.
If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.
Electric Fuel Priming Pump
Illustration 47
typical example
2. Operate fuel priming pump (1). Count the number of operations of the fuel priming pump. After 100 depressions of the fuel priming pump stop.
3. The engine fuel system should now be primed and the engine should now be able to start.
4. Operate the engine starter and crank the engine. After the engine has started, operate the engine at low idle for a minimum of five minutes, immediately after air has been removed from the fuel system.
g01333855
1. Ensure that the fuel system is in working order. Check that the fuel supply valve (if equipped) is in the “ON” position.
NOTICE The electric fuel priming pump will operate for 90 sec­onds. If necessary the electric fuel priming pump can be stoppe eration of the switch.
2. Turn the keyswitch to the “RUN” position. Operate
3. The engine should now be able to start.
4. Operate the engine starter and crank the engine.
Note: Op
help ensure that the fuel system is free of air.
d during the 90 seconds of operation, by op-
the switc 90 seconds of the electric fuel priming pump operation the fuel system will be primed and the electric
After the engine has started, operate the engine at low idle after air has been removed from the fuel system.
h for the electric priming pump. After
fuel priming pump will turn off.
for a minimum of five minutes, immediately
erating the engine for this period of time will
Note: Operating the engine for this period of time will help ensure that the fuel system is free of air.
Note: Do not loosen the high pressure fuel line in order to purge air from the fuel system. This procedure is not required.
Note: Do in order to purge air from the fuel system. This procedure is not required.
not loosen the high pressure fuel line
Page 74
74 SEBU8387 Maintenance Section Fuel System Primary Filter/Water Separator - Drain
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.
After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, “Fuel Injection Lines - Install”.
If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.
i02656272
Fuel System Primary Filter/Water Separator - Drain
Fuel leaked or spilled onto hot surfaces or elec­trical co vent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up f
Ensure that the engine is stopped before any servicing or repair is performed.
mponents can cause a fire. To help pre-
uel spills immediately.
NOTICE
Illustration 48
Typical example
g01334411
2. Install a suitable tube onto drain (1). Open drain
(1). Allow the fluidtodrainintothecontainer.
3. Tighten drain (1) by hand pressure only. Remove
the tube and dispose of the drained fluidinasafe place.
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.
Illustration 49
Typical example
Note: N
ot all primary filters require vent screw (2).
g01371
This primary fuel filter that has a vent screw may be installed on a fuel system that has a low fuel tank.
1. Install a suitable tube onto drain (1). Loosen vent screw (2).
846
Page 75
SEBU8387 75
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
2. Open drain (1). container.
3. Tighten drain the tube and dispose of the drained fluid in a safe place.
4. Tighten vent screw to 6 N·m (53 lb in).
Allow the fluid to drain into the
(1) by hand pressure only. Remove
i02668803
Fuel System Primary Filter (Water Separator) Element ­Replace
Type One Fi lter
Fuel leaked or spilled onto hot surfaces or elec­trical components can cause a fire. To help pre­vent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.
Illustration 50
Typical example
3. Install a suitable tube onto the drain (1). Open the drain (1). Allow the fluidtodrainintothecontainer. Remove the tube.
4. Tighten the drain (1) by hand pressure only.
g01333866
Note: Refer to T esting and Adjusting Manual , “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
NOTICE Ensure that the engine is stopped before any servicing or repair is performed.
After the engine has stopped, you must wait for 60 second be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel line Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace Refer to Disassembly and assembly Manual, “Fuel Injection Lines - Install”.
1. Turn the fuel supply valve (if equipped) to the
OFF position before performing this maintenance. Clean t
2. Place a suitable container under the water
separa spill. Clean up any spilled fuel. Clean the outside of the water separator.
s in order to allow the fuel pressure to
s. If necessary, perform minor adjustments.
any high pressure fuel line that has leaked.
he fuel filter assembly.
tor in order to catch any fuel that might
5. If equipped, remove the wiring harness from the sensor on the bottom of the bowl.
6. Hold bowl (3) and remove screw (2). Remove the bowl from canister (4).
7. Use a suitable tool in order to remove the canister (4). Discard old seals (5 and 6) and the canister in asafeplace.
8. Clean bowl (3).
Page 76
76 SEBU8387 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace
Type Two Filter
Fuel leaked or spilled onto hot surfaces or elec-
ents can cause a fire. To help pre-
spills immediately.
ss of Fuel System Components”
el system.
n order to allow the fuel pressure to
. If necessary, perform minor adjustments.
y high pressure fuel line that has leaked.
NOTICE
Illustration 51
Typical exam ple
g01333552
9. Lubricate the O ring seal (7) with clean engine oil on the new canister. Install the new canister. Do not use a tool in order to install the canister. Tighten the canister by hand. Spin on the canister until the O ring seal contacts the sealing surface. Then rotate the canister ¾ of a turn in order to tighten the canister correctly.
trical compon vent possible injury, turn the start switch off when changing fuel filters or water separator elements. Cleanupfuel
Note: Refer to Testing and Adjusting Manual , “Cleanline for detailed information on the standards of cleanliness that must be observed during ALL work on the fu
After the engine has stopped, you must wait for 60 seconds i be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace an Refer to Disassembly and assembly Manual, “Fuel Injection Lines - Install”.
Ensure that the engine is stopped before any servicing or repair is performed.
10. Install new O ring seal (5) onto setscrew (2). Install new O ring seal (6) into bowl (3).
11. Align the bowl to the canister. Ensure that the sensor (if equipped) is in the correct position. Install setscrew (2). Tighten the setscrew to a torqueof5N·m(44lbin).
12. If equipped, install the wiring harness to the sensor.
13. Remove the container and dispose of the fluid in asafeplace.
14. The secondary filter must be replaced at the same time as the primary filter. Refer to the Operation and Maintenance Manual , “Fuel System Filter ­Replace”.
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.
Page 77
SEBU8387 77
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
Illustration 52
Typical ex
ample
g01370515
3. Install a suitable tube onto the drain (1). Open the drain (1)
.Allowthefluid to drain into the container.
Remove the tube.
4. Tighten t
he drain (1) by hand pressure only.
5. If equipped, remove the wiring harness from the sensor on
the bottom of the bowl (3).
Illustration 53
Typical ex
ample
g01370722
6. Rotate the bowl (3) counterclockwise in order to remove th
e bowl. Remove the O ring seal (2).
Clean the bowl.
Page 78
78 SEBU8387 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace
Illustration 54
Typical ex
ample
g01370724
7. Use a suitable tool in order to remove the old canister
(4).
Illustration 55
Typical ex
ample
g01371107
8. Lubricate the O ring seal (5 ) with clean engine oil on the new
canister. Install the new canister (6). Spin on the canister until the O ring seal contacts the sealing surface. Then rotate the canister 360 degree in
order to tighten the canister correctly.
9. Remove the cap (8) from the threaded end of the new cani
ster and remove the new O ring seal (7).
Install the new O ring seal into the bowl (3).
10. Lubrica
te the O ring seal (7) with clean engine oil. Install the bowl onto the new canister. Tighten the bowlto15N·m(11lbft).
11. If equipped, install the wiring harness to the sensor. Open the fuel supply valve.
12. Remove the container and dispose of the fluid in asafeplace.
13. The secondary filter must be replaced at the same time as the primary filter. Refer to the Operation and Mai
ntenance Manual , “Fuel System Filter -
Replace”.
Page 79
SEBU8387 79
Maintenance Section
Fuel System Secondary Filter - Replace
i02690522
Fuel System Secondary Filter ­Replace
Type One Fi lter
Fuel leaked o trical components can cause a fire. To help pre­vent possible injury, turn the start switch off when changing fue Clean up fuel spills immediately.
Note: Refer t , “Cleanliness of Fuel System Components” for detailed information on the standards of cleanlines work on the fuel system.
Ensure that or repair is performed.
r spilled onto hot su rfaces or elec-
l filters or water separator elements.
o Testing and Adjusting Manual
s that must be observed during ALL
NOTICE
the engine is stopped before any servicing
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”.
1. Ensure that the fuel supply valve (if equipped) is in
the OFF posi
tion. Place a suitable container under the fuel filter in order to catch any fuel that might spill. Clean up any spilled fuel.
This fuel filter can be identified by the six drain holes in the filter. Refer to illustration 56.
Illustration 56
Typical exam ple
g01375918
Illustration 57
Typical example
g01333960
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. 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 80
80 SEBU8387 Maintenance Section Fuel System Secondary Filter - Replace
Type Two 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. Clean up fuel spills immediately.
Note: Refer to T esting and Adjusting Manual , “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
NOTICE Ensure that the engine is stopped before any servicing or repair is performed.
This fuel filtercanbeidentified by the 12 drain holes in the filter. Refer to illustration 58.
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 u
Illustration 59
Typical example
p any spilled fuel.
g01333960
Illustration 58
Typical exam ple
g01375926
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”.
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 81
SEBU8387 81
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 Tanks
Drain the water and the sediment from the fuel storage tank at the following intervals:
Weekly
•
Service inte
•
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, a settle before filling the engine fuel tank. Internal baffles in the bulk storage tank will also help trap sediment. F storage tank helps to ensure the quality of the fuel. When possible, water separators should be used.
rvals
llow adequate time for the sediment to
iltering 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.
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, ma intenance and service in­structions ma y cause personal injury or death.
If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.
Inspect all hoses for leaks that are caused by the following conditions:
Cracking
•
Softness
•
Loose clamps
•
Page 82
82 SEBU8387 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 wire t
•
Outer covering that is ballooning locally
•
Flexible part of the hose that is kinked or crushed
•
Armoring that
•
A constant torque hose clamp can be used in place of any standar 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 loo 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 fitti
•
hat are cracked or soft. Tighten any
ollowing conditions:
hat is used for reinforcement
is embedded in the outer covering
d hose clamp. Ensure that the constant
sen. This can result in leaks. A constant
ng material
1. Stop the engine
2. Loosen the cooling system filler cap slowly in
order to relie system filler cap.
Note: Drain th container. The coolant can be reused.
3. Drain the cool level that is below the hose that is being replaced.
4. Remove the ho
5. Disconnect the old hose.
6. Replace the old hose with a new hose.
7. Install the ho
Note: For the correct coolant, see this Operation and
Maintenance
8. Refill the cooling system. Refer to the OEM information cooling system.
9. Clean the coo cooling system filler cap’s seals. Replace the cooling system filler cap if the seals are damaged. Install the
10. Start the engine. Inspect the cooling system for leaks.
. Allow the engine to cool.
ve any pressure. Remove the cooling
e coolant into a suitable, clean
ant from the cooling system to a
se clamps.
se clamps with a torque wrench.
Manual, “Fluid Recommendations”.
for further i nformation on refilling the
ling system filler cap. Inspect the
cooling system filler cap.
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 following coolant hoses. Refer to the OEM information for further information on the coolant system and the hoses for t
Pressurized System: Hot coolant can cause seri­ous burns. To open t he cooling system filler cap, stop the e components are cool. Loose n the cooling system pressure cap slowly in order to reliev e the pres­sure.
text describes a typical method of replacing
he coolant system.
ngine and wait until the cooli ng system
i02335774
Radiator - C
The radiator is not usually supplied by Perkins. The following text describes a typical cleaning procedure for the rad further information on cleaning the radiator.
Note: Adju the effects of the operating environment.
Inspect th corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the radiator, if necessary.
iator. Refer to the OEM information for
st the frequency of cleaning according to
e radiator for these items: Damaged fins,
lean
Page 83
SEBU8387 83
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 w ater.
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 selection
•
Coolant type and maintenance
•
Environmental qualities
•
Installation
•
The temperature of the fluid in the engine
•
Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if parameters.
Severe servi wear. Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensu full service life.
Due to indivi to identify all of the factors which can contribute to severe service operation. Consult your Perkins dealer or yo maintenance that is necessary for the engine.
The operat procedures and incorrect maintenance procedures can be factors which contribute to a severe service applicati
ing environment, incorrect operating
on.
Environme
Ambient temperatures – Theenginemaybe
exposed to cold environments or hot environments. Valve components can be damaged by carbon buildup if the engin cold temperatures. Extremely hot intake air reduces engine performance.
e is frequently started and stopped in very
ch as power range, speed range,
and maintenance
the engine is operating within the defined
ce operation can accelerate component
re maximum reliability and retention of
dual applications, it is not possible
ur Perkins distributor for the unique
ntal Factors
extended operation in extremely
Severe Service Application ­Check
Severe exceeds the current published standards for that engine. Perkins maintains standards for the following engine
service is the application of an engine that
parameters:
Quality of the air – The engine may be exposed to extended operation in an environment that is dirty or regularly. Mud, dirt and dust can encase components. Maintenance can be very difficult. The buildup can contain
Buildup – Compounds, elements, corrosive chemica
dusty, unless the equipment is cleaned
corrosive chemicals.
ls and salt can damage some components.
Page 84
84 SEBU8387 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 at e
•
Operating at excessive speeds
•
Operating outside the intended application
•
lems can arise when the engine is
.
rating Procedures
xcessive loads
Incorrect Maintenance Procedures
Extending th
•
Failure to use recommended fuel, lubricants and
•
coolant/ant
Starting Mot
Perkins recommends a scheduled inspection of the starting motor. If the starting motor fails, the engine may not start
Check the starting motor for correct operation. Check the electri connections. Refer to the Systems Operation, Testing and Adjusting Manual, “Electric Starting System ­Tes t” fo r m o and for specifications or consult your Perkins dealer or your Perkins distributor for assistance.
e maintenance intervals
ifreeze
i02177969
or - Inspect
in an emergency situation.
cal connections and clean the electrical
re information on the checking procedure
i02718318
Turbocharger - Inspect
NOTICE Turbocharger b 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 ope 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 engi engine operation until the turbocharger is renewed.
Avisualinsp unscheduled downtime. A visual inspection of the turbocharger can also reduce the chance for potential damage to ot
Removal and
Note: The turbochargers that are supplied are
nonservice
For options regarding the removal, installation, and replacemen Perkins distributor. Refer to the Disassembly and Assembly Manual, “Turbocharger - Remove and Turbochar
Inspectin
The compressor housing for the turbocharger must not be remo or removed for the cleaning of the compressor.
1. Remove the
outlet and remove the air intake pipe to the turbocharger. Visually inspect the piping for the presence in order to prevent dirt from entering during reassembly.
earing failures can cause large quanti-
ration should not cause problems as
ne rpm up at no load), do not continue
ection of the turbocharger can minimize
her engine parts.
Installation
able.
t, consult your Perkins dealer or your
ger - Install” for further information.
g
NOTICE
ved from the turbocharger for inspection
pipe from the turbocharger exhaust
of oil. Clean the interior of the pipes
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.
2. Check for obvious heat discoloration of the
turbocharger. Check for any loose bolts or any missing line and the oil drain line. Check for cracks in the housing of the turbocharger. Ensure that the compres
3. Check for the presence of oil. If oil is leaking from
the back possibility of a failed turbocharger oil seal.
bolts. Check for damage to the oil supply
sor wheel can rotate freely.
side of the compressor wheel, there is a
Page 85
SEBU8387 85
Maintenance Section
Walk-Around Inspection
Thepresenceof engine operation at low idle. The presence of oil mayalsobetheresultofarestrictionoftheline for the intake the turbocharger to slobber.
4. Inspect the b outlet for corrosion.
5. Fasten the ai pipe to the turbocharger housing. Ensure that all clamps are installed correctly and that all clamps are tightene
oil may be the result of extended
air (clogged air filters), which causes
ore of the housing of the turbine
r intake pipe and the exhaust outlet
d securely.
i02323090
Walk-Around Inspection
Inspect the Engine for Leaks and for Loose Connections
A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided.
Inspect the wat
•
Note: The water pump seal is lubricated by the coolant in the amount of leakage to occur as the engine cools down and the parts contract.
Excessive coolant leakage may indicate the need to replace the water pump. Remove the water pump. Refer to Disa Remove and Install”. For more information, consult your Perkins dealer or your Perkins distributor.
Inspect the lubrication system for leaks at the front
•
crankshaft seal, the rear crankshaft seal, the oil pan, the oil fi
Inspect the piping for the air intake system and the
•
elbows for c that hoses and tubes are not contacting other hoses, tubes, wiring harnesses, etc.
Ensure that the areas around the rotating parts are
•
clear.
Inspect the alternator belts and any accessory
•
drive belts for cracks, breaks or other damage.
er pump for coolant leaks.
cooling system. It is normal for a small
ssembly and Assembly , “Water Pump -
lters and the rocker cover.
racks and for loose clamps. Ensure
For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections and trash buildup. Make repairs, as needed:
The guards must be in the correct place. Repair
•
damaged guards or replace missing guards.
Wipe all caps and plugs before the engine is
•
serviced in order to reduce the chance of system contamination.
NOTICE For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted.
NOTICE Accumulated grease and/or oil on an engine is a fire hazard. R fer to this Operation and Maintenance Manual, “En­gine - Clean” for more information.
Ensure that the cooling system hoses are correctly
•
clamped and that the cooling system hoses are tight. C pipes.
emove the accumulated grease and oil. Re-
heck for leaks. Check the condition of all
Inspect the wiring harness for damage.
•
Belts for m matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older b the new belt could cause the belt to break.
ultiple groove pulleys must be replaced as
elts are stretched. The additional load on
High Pressure Fuel Lines
Contact with high pressure fuel may cause fluid penetrat el spray may cause a fire hazard. Failure to fol­low these inspection, ma intenance and service in­structi
After the engine has stopped, you must wait for 60 secon be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lin Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replac Refer to Disassembly and assembly Manual, “Fuel Injection Lines - Install”.
ion and burn hazards. High pressure fu-
ons may cause personal injury or death.
ds in order to allow the fuel pressure to
es. If necessary, perform minor adjustments.
e any high pressure fuel line that has leaked.
Page 86
86 SEBU8387 Maintenance Section Water Pump - Inspect
If you inspect t the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance M
Visually inspect the high pressure fuel lines for damage or sig damaged high pressure fuel lines or high pressure fuel lines that have leaked.
Ensure that all clips on the high pressure fuel lines are in place and that the clips are not loose.
Inspect the rest of the fuel system for leaks. Look
•
for loose fuel line clamps.
Drain the water and the sediment from the fuel
•
tank on a daily basis in order to ensure that only clean fuel e
Inspect the wiring and the wiring harnesses for
•
loose conne wires. Check for any loose tie-wraps or missing tie-wraps.
Inspect the ground strap for a good connection and
•
for good condition.
Disconnect any battery chargers that are not
•
protected against the current drain of the starting motor. Che of the batteries, unless the engine is equipped with a maintenance free battery.
Check the condition of the gauges. Replace any
•
gauges that are cracked. Replace any gauge that can not be
he engine in operation, always use
anual, “General hazard Information”.
ns of fuel leakage. Replace any
nters the fuel system.
ctions and for worn wires or frayed
ck the condition and the electrolyte level
calibrated.
Illustration 60
(1) Weep hole
Note: The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and parts contract.
Visually inspect the water pump for leaks. The water pump is not a serviceable item. In order to install a new water pump, refer to the Disassembly and Assembly Manual, “Water Pump - Remove and Install”.
g01249453
i02499304
Water Pum
A failed water pump may cause severe engine overheating problems that could result in the following conditio
•
•
•
ns:
Cracks in the cylinder head
Apistonseizure
Other pot
ential damage to the engine
p - Inspect
Page 87
SEBU8387 87
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i01903596
Emissions Warranty Information
This engine may be certified to comply with exhaust emission standards and gaseous emission standards that are pre manufacture, and this engine may be covered by an Emissions Warranty. Consult your authorized Perkins dealer or yo to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty.
scribed by the law at the time of
ur authorized Perkins distributor in order
Page 88
88 SEBU8387 Index Section
Index
A
After Startin
After Stopping Engine............................................ 42
Aftercooler Core - Clean/Test ................................ 54
Aftercooler C
Alternator - Inspect ................................................ 55
Alternator and Fan Belts - Inspect ......................... 55
Alternator and
B
Battery - Replace................................................... 56
Battery Electr
Battery or Battery Cable - Disconnect ................... 57
Before Starting Engine .................................... 13, 38
Burn Preventio
Batteries............................................................... 9
Coolant................................................................. 9
Oils....................................................................... 9
C
Cold Weather Operation ........................................ 44
Hints for Cold W
Idling the Engine ................................................ 45
Recommendations for Coolant Warm Up .......... 45
Recommendation
Viscosity of the Engine Lubrication Oil............... 44
Cold Weather Starting ........................................... 38
Cooling System C
Change ................................................................ 57
Drain .................................................................. 57
Fill ...................................................................... 58
Flush .................................................................. 58
Cooling System Coolant (ELC) - Change.............. 59
Drain .................................................................. 59
Fill ...................................................................... 60
Flush .................................................................. 60
Cooling System Co
Engines With a Coolant Recovery Tank............. 60
Engines Without a Coolant Recovery Tank........ 61
Cooling System Sup
(SCA) - Test/Add.................................................. 62
Add the SCA, If Necessary ................................ 62
Test for SCA Conce
Crankcase Breather (Canister) - Replace ............. 62
Crushing Prevention and Cutting Prevention ......... 11
D
Diagnostic Flash Code Retrieval ........................... 34
“Diagnostic” Lamp .............................................. 34
Diagnostic Lamp.................................................... 34
Driven Equipment - Check..................................... 63
g Engine ............................................. 40
ore - Inspect...................................... 54
Fan Belts - Replace ....................... 55
olyte Level - Check .......................... 56
n....................................................... 9
eather Operation ...................... 44
s for the Coolant .................... 44
oolant (Commercial Heavy-Duty) -
olant Level - Check ................. 60
plemental Coolant Additive
ntration ............................... 62
E
Electrical Sy
Grounding Practices .......................................... 15
Emergency Stopping ............................................. 42
Emissions Cer
Label for compliant engines ............................... 23
Emissions Warranty Information............................ 87
Engine - Clean....................................................... 6
Engine Air Cleaner Element (Dual Element) -
Clean/Replace ..................................................... 64
Cleaning the Pr
Servicing the Air Cleaner Elements ................... 64
Engine Air Cleaner Element (Single Element) -
Inspect/Repla
Engine Air Cleaner Service Indicator - Inspect...... 66
Test the Service Indicator................................... 67
Engine Air Prec
Engine Description ................................................ 19
Electronic Engine Features................................ 20
Engine Cooling a
Engine Diagnostics ............................................ 20
Engine Specifications......................................... 19
Engine Diagnost
Engine Electronics ................................................. 15
Engine Lifting......................................................... 24
Engine Mounts - In
Engine Oil and Filter - Change .............................. 68
Drain the Engine Lubricating Oil ........................ 69
Fill the Oil Pan.................................................... 70
Replace the Oil Filter ......................................... 69
Engine Oil Level - Check ....................................... 67
Engine Oil Sample
Obtain the Sample and the Analysis .................. 68
Engine Operation................................................... 41
Engine Operation w Engine Operation with Intermittent Diagnostic
Codes .................................................................. 37
Engine Starting ................................................ 13, 3
Engine Stopping .............................................. 14, 42
Engine Storage...................................................... 24
Engine Valve Lash - I
F
Fan Clearance - Check.......................................... 71
Fault Logging......................................................... 36
Features and Controls ........................................... 28
Fire Prevention and Explosion Prevention .............. 9
Fire Extinguisher ................................................. 1
Lines, Tubes and Hoses ..................................... 11
Fluid Recommendation s ........................................ 48
Engine Oil .......................................................... 49
General Lubricant Information ........................... 48
stem ................................................... 14
tification Film .................................. 23
imary Air Cleaner Elements ...... 65
ce................................................... 66
leaner - Check/Clean.................... 67
nd Lubrication ......................... 20
ics................................................ 34
spect........................................ 67
- Obtain ................................... 68
ith Active Diagnostic Codes ... 36
nspect/Adjust ....................... 70
3
8
1
Page 89
SEBU8387 89
Index Section
Foreword ................................................................. 4
California Proposition 65 Warning ....................... 4
Literature Information ........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 4
Safety................................................................... 4
Fuel and the Effect from Cold Weather ................. 46
Fuel Conservati
Fuel Related Components in Cold Weather .......... 47
Fuel Filters ......................................................... 47
Fuel Heaters ...................................................... 47
Fuel Tanks.......................................................... 47
Fuel System - Prime.............................................. 72
Electric Fuel Pri
Hand Fuel Priming Pump................................... 73
Fuel System Primary Filter (Water Separator)
Element - Replace
Type One Filter .................................................. 75
Type Two Filter................................................... 76
Fuel System Prima
Drain .................................................................... 74
Fuel System Secondary Filter - Replace ............... 79
Type One Filter .................................................. 79
Typ e Two filter.................................................... 80
Fuel Tank Water and Sediment - Drain ................. 81
Drain the Water and
Fuel Storage Tanks ............................................ 81
Fuel Tank ........................................................... 81
G
Gauges and Indic ators .......................................... 26
General Hazard Information .................................... 7
Containing Fluid S
Fluid Penetration.................................................. 8
Pressure Air and Water........................................ 8
General Informatio
H
High Pressure Fuel Lines ...................................... 12
Hoses and Clamps - In
Replace the Hoses and the Clamps .................. 82
I
Important Safety I
L
Lifting and Storage ................................................ 24
on Practices.......... ........................ 41
ming Pump................................ 73
............................................... 75
ry Filter/Water Separator -
the Sediment..................... 81
pillage ..................................... 8
n............................................... 17
spect/Replace ................... 81
nformation ................................... 2
M
Maintenance Interval Schedule ............................. 53
Maintenance Se
Model View Illustrations ......................................... 18
Model Views .......................................................... 18
Monitoring Sys
Programmable Options and Systems
Operation ......................................................... 28
Mounting and Di
O
Operation Section.................................................. 24
Overspeed ............................................................. 33
P
Plate Locations and Film Locations....................... 22
Serial Number P
Product Identification Information .......................... 22
Product Information Section .................................. 17
R
Radiator - Clean .................................................... 82
Reference Numbers .............................................. 22
Record for Refe
Refill Capacities..................................................... 48
Cooling System.................................................. 48
Lubrication Sys
S
Safety Messages ..................................................... 5
(1) Universal Wa
(2) Ether Warning................................................. 6
(3) Hand (High Pressure) ... .................................. 7
Safety Section ......................................................... 5
Self-Diagnostics..................................................... 34
Sensors and Electrical Components ..................... 29
Coolant Temperat
Engine Oil Pressure Sensor 6............................ 32
Failure of Sensors.............................................. 32
Fuel Pressure Sen
Intake Manifold Air Temperature Sensor 2......... 32
Intake Manifold Pressure Sensor 3.................... 32
Primary Speed/Ti
Programmable Monitoring System (PMS) ......... 32
Secondary Speed/Timing Sensor 8 ................... 33
Sensor Locations ............................................... 2
Severe Service Application - Check ...................... 83
Environmental Factors ....................................... 83
Incorrect Mainten
Incorrect Operating Procedures......................... 84
Starting Motor - Inspect ......................................... 84
ction ............................................. 48
tem........................................... 28–29
smounting..................................... 11
late (1) ..................................... 22
rence......................................... 22
tem ............................................ 48
rning .......................................... 5
ure Sensor 1 .......................... 32
sor 4 ..................................... 32
ming Sensor 7 ........................ 33
ance Procedures .................... 84
9
Page 90
90 SEBU8387 Index Section
Starting the En
Starting the Engine ............................................ 38
Starting with Jump Start Cables ............................ 39
Stopping the En
T
Table of Contents..................................................... 3
Turbocharger -
Inspecting........................................................... 84
Removal and Installation.................................... 84
W
Walk-Around Inspection ........................................ 85
High Pressure Fuel Lines................................... 85
Inspect the Eng
Connections ..................................................... 85
Warranty Information ............................................. 87
Warranty Secti
Water Pump - Inspect ............................................ 86
Welding on Engines with Electronic Controls ........ 17
gine ................................................ 38
gine .............................................. 42
Inspect .......................................... 84
ine for Leaks and for Loose
on ................................................... 87
Page 91
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
Page 92
Copyright © 2007 Perkins Engine Company Limited All Rights Reserved PrintedinU.
K.
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use