Perkins Engine 1106D Service Manual

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Page 1

Operation and Maintenance Manual

SEBU8119-02

January 2008

1106D Industrial Engine

(Engine)

Page 2

Important Safety Information

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

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

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

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

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

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

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this product Perkins recommends using Perkins

replacement parts.

Failure to heed this warning can lead to premature failures, product damage, personal injury or

death.

Page 3

SEBU8119-02 3

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 S ecti

Warranty Information .......................................... 100

terval Schedule ............................ 65

Index Section

Index ................................................................... 101

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 Indicators .............................. ............ 26

Features and Controls .......................................... 28

Engine Diagnostics ............................................... 35

Engine Starting ..................................................... 39

Engine Operation .................................................. 42

Engine Stopping ................................................... 43

Cold Weather Operation ....................................... 45

Maintenance Section

Reﬁll Capacities .................................................... 49

Page 4

4 SEBU8119-02 Foreword

Foreword

Literature Information

This manual con lubrication and maintenance information. This manual should be stored in or near the engine area in a literatur study and keep it with the literature and engine information.

English is the primary language for all Perkins publications. The English used facilitates translation and consiste

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

Safety

This safety section lists basic safety precautions. In addition, this section identiﬁes hazardous, warning si precautions listed in the safety section before operating or performing lubrication, maintenance and repair on

this product.

tains safety, operation instructions,

e holder or literature storage area. Read,

ncy.

or attachments that may be different

t and advancement of product design

arding your engine, or this manual, please

tuations. Read and understand the basic

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

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

ive maintenance program is followed, a

mize operating costs through cost

rvice should be performed at the

lso governs the Maintenance Interval

t lubrication and maintenance than is

Maintenance Intervals

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

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

ce schedules be reproduced and displayed

the engine’s permanent record.

tor can assist you in adjusting your

Overhaul

Operatio

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

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

ey assist with developing the skills and

as the operator gains knowledge of the

ation section is a reference for operators.

pping the engine. This section also includes a

Maintenance

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

ntenance section is a guide to engine care.

als. Items in the maintenance schedule are

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

nterval and the maintenance items in that

erkins distributor offers a variety of options

ailure overhaul options available. Consult with

California Proposition 65 Warning

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

defects, and other reproductive harm. Battery

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

Page 5

SEBU8119-02 5

Safety Section

Safety Messages

Safety Section

i02788195

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 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 distributor can

(1) Un iversal Warning

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

ead and understand the instructions

warnings could result in serious injury

Illustration 1

lexample

Typica

The Universal Warning label (1) is located on both sides o

f the valve mechanism cover base.

g01154807

Page 6

6 SEBU8119-02 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.

g01392790

Illustration 3

Typical examp le

g01154809

The ether warning label (2) is located on the cover of the inlet manifold.

Page 7

SEBU8119-02 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-

g01392789

The warning label for the Hand (High Pressure) (3) is located o

n the top of the fuel manifold.

i023284

General Hazard Information

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 SEBU8119-02 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 from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps.

g00702020

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

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

ed air and/or water is used for

efaceshield.

205 kPa (30 psi). The maximum

Fluid Penetration

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

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

lic ﬂuid or items such as pipe plugs to

any hydraulic components or parts

or parts until pressure has been relieved

e hydraulic pressure.

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

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Report all necessary repairs.

Do not allow unauthorized personnel on the equipment.

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

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

Pressure Air and Water

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

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

Illustration 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

SEBU8119-02 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 h igh 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.

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 and 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 SEBU8119-02 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 ﬂ ame 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 h igh 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

SEBU8119-02 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.

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

Chips or other debris may ﬂy off objects when objects are struck. Before objects are struck, ensure that no one will 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 SEBU8119-02 Safety Section High Pressure Fuel Lines

i02668808

High Pressure Fuel Lines

Contact with h igh 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 haz ard. Failure to fol-

Illustration 1 2

(1)Highpressureline (2)Highpressureline (3)Highpressureline

(4) High pressure line (5) High pressure line (6) High pressure 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

SEBU8119-02 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

i02813489

Before Starting Engine

Before the init serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplish 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.

ialstart-upofanenginethatisnew,

ed 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 in an explosion and personal injury.

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

Page 14

14 SEBU8119-02 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 t he 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

SEBU8119-02 15

Safety Section

Engine Electronics

Grounding Practices

Illustration 13

Typical examp le

(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 Electronics

Illustration 14

Typical examp le

(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.

Tampering

with the electronic system ins tallation 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 SEBU8119-02 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

SEBU8119-02 17

Product Information Section

General Information

Product Information Section

General Infor mation

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 m inimum 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. T he current ﬂow from the welder to the ground clamp of the welder will not c ause damage to any associated components.

(1) Engine (2) Welding rod (3) Keyswit ch in the OFF position (4) Battery disconnect switch in the open position (5) Disconnected battery cables (6) Battery (7) Electrical/Electronic component (8) Maximum distance between the c ompo nent that is being

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

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 ﬂow 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 SEBU8119-02 Product Information Section Model Views

Model Views

i02786384

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 im ary fue l ﬁlter (8) Oil sampling valve (9) Oil ﬁlter (10) Fuel pump

g01391892

(11) Water pump (12) Damper (13) Fan (14) Fan pulley (15) Belt tensioner

Page 19

SEBU8119-02 19

Product Information Section

Model Views

Illustration 1 7

Rear right engine view

(16) Oil gauge (17) Air intake (18) Oil 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 PJ 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

•

g01391893

(26) Oil pan (27) Drain plug (oil) (28) Drain plug or coolant sampling valve (29) Breather (30) Rear 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 SEBU8119-02 Product Information Section Model Views

Illustration 18

1106 Electronic Engine model PJ

(A) Exhaust valves (B) Inlet valves

Table 1

1106 Electronic Engine Model PJ 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 operating 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

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

SEBU8119-02 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, efﬁciency of emission controls, and

mance and efﬁciency also depend on

ntenance Interval Schedule” for more

Page 22

22 SEBU8119-02 Product Information Section Product Identiﬁcation Information

Product Identiﬁcation Information

Plate Locations and Film Locations

i02650956

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 PJ*****U000001J.

*****

____________________ The list number for the engine

__________________________________________ Type of engine

____________________________ Built in the United Kingdom

000001

___________________________ 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 al Lu br

Total Cooling System Capacity _________________________

l Load rpm

Fuel Filter Element

_____________________________________

__________________________

ication System Capacity

_____________________

Air Cleaner Element _______________________________________

Page 23

SEBU8119-02 23

Product Information Section

Product Identiﬁcation Information

Fan Drive Belt _

_____________________________________________

Alternator Belt ______________________________________________

i02894856

Emissions Certiﬁcation Film

Label for compliant engines

Typical examp

les of emissions labels

Illustration 2 1

g01440937

Page 24

24 SEBU8119-02 Operation Section Lifting and Storage

Operation Section

Lifting and Storage

Engine Lifting

i02164186

Some removals r obtain correct balance and safety.

To r e m 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

SEBU8119-02 25

Operation Section

Lifting and Storage

Personal injury can result from 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.

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

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

5. Operate the engine until the engine reaches

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

6. Drain the lubricating oil from the oil pan.

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

9. If equipped, re element. Seal the end of the breather pipe.

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

11. Remove the glow plugs. Slowly rotate the crankshaft. By checking the valves, position the piston at 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 to protect the engine against corrosion. If 1762811 POWERPART Lay-Up 2 is not available, use a preservative of the correct speciﬁcation instead of the lubricating oil. If a preservative is used, this must be drained completely at the end of the storage period and the oil pan must be reﬁlled to the correct level with normal lubricating oil.

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

8. Disconnect the battery. Ensure that the battery is

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

Page 26

26 SEBU8119-02 Operation Section Gauges and Indicators

Gauges and Ind icators

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

SEBU8119-02 27

Operation Section

Gauges and Indicators

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

Page 28

28 SEBU8119-02 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 indic ator 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 O ptions and Systems Operation

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

The engine can be programmed to the following modes:

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

For each of the programmed modes, refer to Trouble information on Indicator Lamps.

For m ore your Perkins dealer or your Perkins distributor.

verify the condition.

shooting , “Indicator Lamps” for more

information or assistance for repairs, consult

Page 29

SEBU8119-02 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 w ill illuminate for 2 seconds only.

No faults There are no active diagnostic faults.

Active diagnostic fault

Warning One or more of the engine protection values

Derate and warning

Engine shutdown

An active diagnostic fault has been detected.

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

has been exceeded.

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

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

een detected.

The engine has not been started.

Theengineisrunning normally.

Theengineisrunning but the engine has been derated.

Theengineisrunning normally.

Theengineisrunning but the engine has been derated.

The engine is shutdown or shutdown is imminent.

i02788240

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 SEBU8119-02 Operation Section Features and Controls

Illustration 2 3

(1) Coolant tempe rature sensor (2) Intake manifold air tem perature sensor (3) Intake manifold pressure sensor

(4) Fuel pressure sensor (5) Electronic control mod ule (ECM) (6) Oil pressure sensor

g01392818

(7) Primary pos ition sensor (8) Secondary position sensor

Page 31

SEBU8119-02 31

Operation Section

Features and Controls

Illustration 2 4

(1) Coola (2) Intak

nt temperature sensor

e manifold air temperature 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 SEBU8119-02 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).

Electronic Control Module 5

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

The ECM adjusts injection timing and fuel pressure for the best engine performance, the best fuel economy

Engine O

The engine oil pressure sensor is an absolute pressur pressure in the main oil gallery. The engine oil pressure sensor detects engine oil pressure for diagno sends a signal to the ECM (5).

data that is input from the sensors of the

and the best control of exhaust emissions.

il Pressure Sensor 6

e sensor that measures the engine oil

stic purposes. The engine oil pressure sensor

Page 33

SEBU8119-02 33

Operation Section

Features and Controls

Low Oil Pressur

The setpoint for the low pressure warning is dependent upo active and logged only if the engine has been running for more than 8 seconds.

e Warning

n the engine speed. The fault will be

Very Low Oil Pressure Warning

The very low oi upon the engine speed. If the DERATE mode of the engine monitoring system is selected, the ECM (5) will derate t will be limited.

Failure of th

The ECM (5) will detect failure of the engine oil pressure sen about the status of the engine oil pressure sensor. The engine oil pressure related strategies will be disabled in pressure sensor. A failure of the engine oil pressure sensor will not cause a shutdown of the engine or any horsep operation of the sensor, refer to Troubleshooting, “5 Volt Sensor Supply Circuit - Test”.

l pressure setpoint is dependent

he engine power. The engine horsepower

e Engine Oil Pressure Sensor

sor. The diagnostic lamp warns the user

the event of a failure of the engine oil

ower change. In order to check the correct

Primary Speed/Timing Sensor 7

If the ECM (5) does not receive a signal from the primary speed/timing sensor , the “DIAGNOSTIC” lamp will i logged in the ECM memory.

If the ECM speed/timing sensor (7), the ECM will read the signal from the secondary speed/timing sensor (8). The ECM conti is a signal from both sensors.

ndicate a diagnostic fault code which will be

does not receive a signal from the primary

nually checks in order to determine if there

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”.

i02858345

Engine Shutoffs and E ngine Alarms

Shutoffs

The shutoffs are electrically operated or mechanically operated. The electrically operated shutoffs are controlled by the ECM.

Shutoffs are set at critical levels for the following items:

Operating temperature

•

Operating pressure

•

Operating level

•

Operating rpm

•

The particular shutoff may need to be reset before theenginewillstart.

Intermi engine control.

Failure

ttent failure of the sensors will cause erratic

of the Primary Speed/Timing

Sensor

Correct sensor is essential. Software in the ECM protects against reverse running of the engine. If the primary speed/ protection against reverse running. In some applications, it is possible for the transmission to run the engine immediately. Turn the keyswitch to the “OFF” position.

In order to check the correct operation of the sensor, refer to Troubleshooting, “Engine speed/Timing senso

operation of the primary speed/timing

timing sensor fails there is no automatic

engine in reverse. In this event, Stop the

r-Test”.

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

Be familiar with the following items:

Types and locations of shutoff

•

Conditions which cause each shutoff to function

•

The resetting procedure that is required to restart

•

the engine

Alarms

The alarms are electrically operated. The operation of the alarms are controlled by the ECM.

Page 34

34 SEBU8119-02 Operation Section Features and Controls

The alarm is ope When the sensor or the switch is activated a signal is sent to the ECM. An event code is created by the ECM. The EC illuminate the lamp.

Your engine m sensors or switches:

Coolant leve

indicates when the coolant level is low.

Coolant temp

sensor indicates high jacket water coolant temperature.

Intake manifold air temperature – The intake manifold air temperature sensor indicates high intake air tempera

Intake manifold pressure – The intake manifold pressure se engine manifold.

Fuelrailpr

checks for high pressure or low pressure in the fuel rail.

Engine oil pressure – The engine oil pressure sensor indicates when oil pressure drops below rated system pre

rated by a sensor or by a switch.

Mwillsendasignalinorderto

ay be equipped with the following

l–The low coolant level switch

erature – The coolant temperature

ture.

nsor checks the rated pressure in the

essure – The fuel rail pressure sensor

ssure, at a set engine speed.

If corrective m reasonable time, engine damage could result. The alarm will continue until the condition is corrected. The alarm may n

easures are not taken within a

eed to be reset.

Testing

TurningthekeyswitchtotheONpositionwillcheck the indicato indicator lights will be illuminated for two seconds after the keyswitch is operated. Replace suspect bulbs immedi

Refer to Troubleshooting for more information.

r lights on the control panel. All the

ately.

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.

Engine overspeed – The primary speed/timing sensor che activated at 3000 RPM.

Air ﬁlter

ﬁlter when the engine is operating.

User deﬁn

the engine remotely.

Water in f

in t he primary fuel ﬁlter when the engine is operating.

Note: The temperature switch must be submerged in coolant in order to operate.

Engines may be equipped with alarms in order to alert the operator when undesirable operating conditi

When an alarm is activated, corrective measures must be taken before the situation becomes an emergency in order

cks the engine speed. The alarm is

restriction – The switch checks the air

ed switch – This switch can shut down

uel switch – This switch checks for water

sensing element of the coolant

ons occur.

NOTICE

to avoid possible engine damage.

Page 35

SEBU8119-02 35

Operation Section

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

i02857828

Diagnostic Flash Code Retrieval

“Diagnostic” Lamp

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

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

1. 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 36

36 SEBU8119-02 Operation Section Engine Diagnostics

Table 3

Flash Codes for 1106D Industrial Engine

Diagnostic

Effect On Engine Performance

(2)

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

Temperature sensor

(5)

fault

141 Primary Engi

Speed/Timing Sensor

(6)

Fault

142 Secondary Engine

Speed/Timing Sensor Fault

143 Engine Timing

Calibration Fault

144

Engine Operation Mode

Selector Switch Fault

151 High Air Filter

Restriction

154 Throttle Position sensor

Fault

155 Secondary Throttle

Position sensor Fault

157

Engine Oil Pressure

Sensor Fault

159 Fuel Rail

Pressure

Sensor Fault

162 Fuel Rail Pressure

enoid Fault

168

Val v e So l

Engine Coolant

XX X

Temperature Sensor Faul

169 Low Engine Coolant X X

177 Turbo Wastegate

Actuator Fault

185 High Exhaust

Temperature

197

Intake Manifold Boost

Pressure Fault

(1)

Engine

Shutdown

Suggested Operator Action

(3)

Service

Schedule

a Service.

(continued)

(4)

Page 37

SEBU8119-02 37

Operation Section

Engine Diagnostics

(Table 3, contd)

199

415 Incorrect Engine

426

429 Ignition Key Switch

511

514 SAE J1939 Data Link

516

517

527

(1)

If warning lamps ar e installed refer to this table. For installations that have electronic displays, refer to the O EM for information.

(2)

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

(3)

The operato

(4)

Schedule Service: The problem should be investigated when 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 primar immediately “Engine spe

(6)

The engine will not start.

Glow Plug Start Relay Fault

Software

Machine Security System Module Fault

Fault

ECM Power Supply Voltage Fault

Fault

5 Volt Sensor DC Power Supply Fault

8 Volt Sensor DC Power Supply Fault

Customer/S Parmeter Fault

r should go to the nearest location that has a qualiﬁed service program.

y engine speed/timing sensor fails there is no automatic protection against reverse running. In this event, Stop the engine

. Turn the keyswitch to the “OFF” position. In order to check the correct operation of the sensor, refer to Troubleshooting,

ed/Timing sensor - Test”.

ystem

(6)

XX X X

XX X

i01902949

Fault Logging

The system p When the Electronic Control Module (ECM) generates an active diagnostic code, the code will be logged in that have been logged by the ECM can be identiﬁed by the electronic service tool. The active codes that have been l has been rectiﬁed or the fault is no longer active. The following logged faults can not be cleared from the memory password: Overspeed, low engine oil pressure, and high engine coolant temperature.

rovides the capability of Fault Logging.

the memory of the ECM. The codes

ogged will be cleared when the fault

of the ECM without using a factory

i02651197

Engine Operation with Active Diagnostic

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

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

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

he speciﬁcation. Use the electronic service

iagnostic code should be investigated.

aired and there is only one active

of the engine and performance of the

niﬁcantly slower and power outputs may

ion on the relationship between each active

Codes

Page 38

38 SEBU8119-02 Operation Section Engine Diagnostics

i01902995

Engine O peration 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 Co des

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 39

SEBU8119-02 39

Operation Section

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 Eng ine

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

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 o f 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 start.

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 in an explosion and personal injury.

Startability will be improved at temperatures below

−18 °C (0 °F) from the use of a jacket water heater

or extra battery capacity.

Page 40

40 SEBU8119-02 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 e nds 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 41

SEBU8119-02 41

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 batterie 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 42

42 SEBU8119-02 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 Practices

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

Avoid spilling fuel.

•

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

Be aware of the properties of the different fuels.

•

Use only the recommended fuels.

Avoid unnecessary idling.

•

Shut off the time.

Observe the

•

Keep the air cleaner elements clean.

Maintain th

•

f the engine can affect the fuel

ons. Follow the recommended procedures

when the fuel is warmed up. The fuel

engine rather than idle for long periods of

air cleaner service indicator frequently.

e electrical systems.

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 43

SEBU8119-02 43

Operation Section

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 may 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 44

44 SEBU8119-02 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 45

SEBU8119-02 45

Operation Section

Cold Weather Operation

i02717265

Cold Weather O perat ion

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

The type of fuel that is used

•

The viscosity of the engine oil

•

The operation of the glow plugs

•

Optional Cold starting aid

•

Battery condition

•

This section will cover the following information:

Potential problems that are caused by cold weather

•

operation

Suggest steps which can be taken in order to

•

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

Install the cor

•

before the beginning of cold weather.

Check all rubb

•

weekly.

Check all elec

•

fraying or damaged insulation.

Keep all batte

•

Fill the fuel tank at the end of each shift.

•

Check the air cleaners and the air intake daily.

•

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

Ensure that the glow plugs are in working order.

•

Refer to Test

-Test”.

Personal injury or property damage can result from alcohol or starting ﬂuids.

Alcohol or starting ﬂuids are highly ﬂammable and toxic and if improperly stored could result in injury or property

rect speciﬁcation of engine lubricant

er parts (hoses, fan drive belts, etc)

trical wiring and connections for any

ries fully charged and warm.

ing and Adjusting Manual, “Glow Plug

damage.

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

Weather conditions

•

Engine applications

•

Recommendations from your Perkins dealer or your Perkins distributor are based on past proven practices. The information that is contained in this section provides guidelines for cold weather operation.

Hints for Cold Weather Operation

If the engine will start, operate the engine until a

•

minimum operating temperature of 81 °C (177.8 °F) is achieved. Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking.

The cooling system and the lubrication system

•

for the engine do not lose heat immediately upon shutdown. This means that an engine can be shut downforaperiodoftimeandtheenginecanstill have the ability to start readily.

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

Forjumpstartingwithcablesincoldweather,

•

refer to the Operation and Maintenance Manual, “Starting with Jump Start Cables.” for instructions.

Viscosity of the Engine Lubrication Oil

Correct engine oil viscosity is essential. Oil viscosity affects the amount of torque that is needed to crank the engine. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended viscosity of oil.

Recommendations for the Coolant

Provide cooling system protection for the lowest expected outside temperature. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended coolant mixture.

Page 46

46 SEBU8119-02 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 ﬂ ows around the engine under

s reached the correct minimum operating

mperature regulator opens further allowing

passage between the cylinder block and

age, and reduction in fuel economy.

Page 47

SEBU8119-02 47

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 t he 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 48

48 SEBU8119-02 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

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 49

SEBU8119-02 49

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 t he approximate capacities for the crankcase oil sump (aluminum) which includes the standard factory installed oil ﬁlters. Engines with auxiliary oil ﬁlters will require additional oil. Refer to the OEM speciﬁcations for the capacity of the auxiliary oil ﬁlter.

(1)

Cooling System

Minimum Maximum

13.5 L

(2.9696

Imp gal)

16.5 L

(3.6295

Imp gal)

i02788820

Fluid Recommendations (Fuel Speciﬁca

Glossary

•

ISO Internati

•

ASTM American Society for Testing and Materials

•

HFRR High Frequency Reciprocating Rig for

•

Lubricity testing of diesel fuels

FAME Fatty Acid Methyl Esters

•

CFR Co-ordina

•

LSD Low Sulfur Diesel

•

ULSD Ultra Low Sulfur Diesel

•

RME Rape Methy

•

SME Soy Methyl Ester

•

EPA Environmental Protection Agency of the

•

United States

General Information

Every attempt is made to provide accurate, up to date information. Perkins Engines Company Limited is not responsible forerrorsoromissions.

onal Standards Organization

ting Fuel Research

By use of this document you agree that

tion)

lEster

NOTICE

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 radiator or an expansion tank w ith the following com ponents: heat exchanger 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)

NOTICE These recommendations are subject to change without notice. Contact your local Perkins distributor for the most up to date recommendations.

Diesel Fuel R

Satisfactory engine performance is dependent on theuseofago quality fuel will give the following results: long engine life and acceptable exhaust emissions levels. The fuel must me stated in table 6.

The footnotes are a key part of the Perkins Speciﬁcation for Dis footnotes.

et the minimum requirements that are

tillate Diesel Fuel Table. Read ALL of the

equirements

od quality fuel. The use of a good

NOTICE

Page 50

50 SEBU8119-02 Maintenance Section Reﬁll Capacities

Table 6

Perkins Speciﬁcation for Distillate Diesel Fuel

Property UNITS Requirements “ASTM”Test “ISO”Test

Aromatics %Volume 35% maximum D1319 “ISO”3837

Ash

Carbon Residue on

%Weight 0.01% maximum

%Weight 0.35% maximum

D482

D524

10% Bottoms

Cetane Number

(2)

Cloud Point °C

40 minimum

The cloud point must

D613/D6890 “ISO”5165

D2500 not exceed the lowest expected ambient temperature.

Copper Strip

No. 3 maximum D130 “ISO”2160

Corrosion

Density at 15 °C (59 °F)

Distillati

(3)

Kg / M

°C 10% at 282 °C

801 minimum and 876 maximum

No equivalent test

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

Flash Point °C legal limit D93 “ISO”2719

Thermal Stability

Minimum of 80%

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

Pour Point

°C 6°C(42.8°

F) minimum

D97 below ambient temperature

(1)(4)

Sulfur

Kinematic Viscosity

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

(5)

“MM”2“/S (cSt)” The viscosity of the

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

Water and sediment

Water

% weight 0.1% maximum

Sediment % weight 0.05% maximum

D1796

D1744 No equivalent test

D473

(1)

“ISO”6245

“ISO”4262

“ISO”3015

“ISO 3675 ”“ISO 12185”

“ISO”3016

“ISO”3734

“ISO”3735

(continued)

Page 51

SEBU8119-02 51

Maintenance Section

Reﬁll Capacities

(Table 6, contd)

Gums and Resins

Lubricity corrected

(6)

mg/100mL

wear scar diameter at 60 °C (140 °F).

(1)

This speciﬁca “ASTM D5453”, Diesel (LSD). test m ethods”

(2)

A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather.

(3)

“Via standards tables, the equivalent API gravity for the minimum density of 801 kg / m3(kilograms per cu bic meter) is 45 and for the maximum density of 876 kg / m

(4)

Regional regu regulations b fuels. Fuel su Fuel sulfur le recommendati

(5)

The values of the fuel viscosity are the values as the fuel is delivered to the f uel injection pumps. Fuel should also meet the minimum viscosity requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of e ither the “ASTM D445” test method or the “ISO 3104” test m ethod. If a fuel with a low v iscosity is used, cooling of the fuel may be required to maintain 1.4 cSt or greater viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to 4.5 cSt at the fuel injection pump.

(6)

Follow the test conditions and pr ocedures for gas oline (motor).

(7)

The lubricit or ASTM D6079 consult your can cause pro

(7)

tion includes the requirements for Ultra Low S ulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to

“ASTM D2622”, or “ISO 20846, ISO 20884” test methods. This speciﬁcation includes the requirements for Low Sulfur

LSD fuel will have ≤500 ppm (0.05%) sulfur. Refer to following:“ASTM 5453, AS TM D2622”, “ISO 20846”, and “ISO 20884

lations, national regulations or international regulations can requ ire a fuel with a speciﬁc sulfur limit. Consult all applicable

efore selecting a fuel for a given engine application. Perkins fuel systems and engine components can operate on high sulfur

lfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal components.

vels above 0.5% may signiﬁcantly shorten the oil change interval. For additional information, refer to this manual, “Fluid

ons (General lubricant Information)”.

y of a fuel is a concern with low sulfur and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1

High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements,

fuel supplier. Do not treat the fuel w ithout c onsulting the fuel supplier. Some additives are not compatible. These additives

blems in the fuel system.

is 30”.

10 mg per 100 mL

D381

maximum

0.52 maximum D6079

“ISO”6246

“ISO”12156-1

NOTICE

Operating wi

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

uced service life of the fuel system, deposits in the combustion chamber, and reduced service life of the engine.

Diesel Fuel Characteristics

Perkins Recommendation

Cetane Numb

Fuel that has a high cetane number will give a shorter ignition de quality. Cetane numbers are derived for fuels against proportions of cetane and heptamethylnonane in the standard C test method.

Cetane num expected from current diesel fuel. However, a cetane number of 40 may be experienced in some territories. The Unite that can have a low cetane value. A minimum cetane value of 40 is required during average starting conditio for operations at high altitudes or in cold weather operations.

lay. This will produce a better ignition

d States of America is one of the territories

ns. A higher cetane value may be required

FR engine. Refer to “ISO 5165” for the

bers in excess of 45 are normally

Fuel with a lo

w cetane number can be the root cause

of problems during cold start.

Viscosity

Viscosity is the property of a liquid of offering resistance increasing temperature. This decrease in viscosity follows a logarithmic relationship for normal fossil fuel. The c This is the quotient of the dynamic viscosity that is divided by the density. The determination of kinematic viscosity viscometers at standard temperatures. Refer to “ISO 3104” for the test method.

The viscosity of the fuel is signiﬁcant because fuel serves as a lubricant for the fuel system components. Fuel must the fuel system in both extremely cold temperatures and extremely hot temperatures. If the kinematic viscosit injection pump damage to the fuel injection pump can occur. This damage can be excessive scufﬁng and seiz restarting, stalling and loss of performance. High viscosity may result in seizure of the pump.

Perkins recommends kinematic viscosities of 1.4 and

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

to shear or ﬂow. Viscosity decreases with

ommon reference is to kinematic viscosity.

is normally by readings from gravity ﬂow

have sufﬁcient viscosity in order to lubricate

y of the fuel is lower than 1.4 cSt at the fuel

ure. Low viscosity may lead to difﬁcult hot

Page 52

52 SEBU8119-02 Maintenance Section Reﬁll Capacities

Density

Density is the mass of the fuel per unit volume at a speciﬁcte

mperature. This parameter has a direct inﬂuence on engine performance and a direct inﬂuence on emissions. This determines the heat output from a

given injected volume of fuel. This is generally quoted in the following kg/m at 15 °C (59 °F).

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

eptable but these fuels will not produce

the rated power.

Sulfur

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

By using th D2622, or ISO 20846 ISO 20884”, the content of sulfur in low sulfur diesel (LSD) fuel must be below 500 PPM 0.0 D5453, ASTM D2622, or ISO 20846 ISO 20884”, the contentofsulfurinultralowsulfur(ULSD)fuelmust be below 1 the use of ULSD fuel are acceptable provided that the fuels meet the minimum requirements that are stated in exceed wear scar diameter of 0.52 mm (0.0205 inch). The fuel lubricity test must be performed o n a HFRR, operate

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

When on be necessary that high alkaline lubricating oil is used in the engine or that the lubricating oil change inter Maintenance Manual, “Fliud Recommendations (Genernal Lubrication Information)” for information on sul

ns. Regional regulation, national regulations

l quality must comply with all existing local

e test methods “ASTM D5453, ASTM

5%. By using the test methods “ASTM

5 PPM 0.0015%. The use of LSD fuel and

table 6. The lubricity of these fuels must not

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

fur fuels above 0.5% by mass might only

ive impact on emissions of particulates.

n be used in countries that do not regulate

ly high sulfur fuels are available, it will

val is reduced. Refer to this Operation and

fur in fuel.

Lubricity

This is the capability of the fuel to prevent pump wear. The ﬂuid

’s lubricity describes the ability of the ﬂuid to reduce the friction between surfaces that are under load. This ability reduces the damage that is caused by fri

ction. Fuel injection systems rely on the lubricating properties of the fuel. Until fuel sulfur limits were mandated, the fuel’s lubricity was generally believedtob

e a function of fuel viscosity.

The lubricity has particular signiﬁcance to the current low viscosit

y fuel, low sulfur fuel and low aromatic fossil fuel. These fuels are made in order to meet stringent exhaust emissions. A test method for measuring t

he lubricity of diesel fuels has been developed and the test is based on the HFRR method that is operated at 60 °C (140 °F). Refer to “ISO 12156 p

art 1 and CEC document F06-A-96” for

the test method.

Lubricity

wear scar diameter of 0.52 mm (0.0205 inch) MUST NOT be exceeded. The fuel lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to “I

SO 12156-1 ”.

Fuel additives can enhance the lubricity of a fuel. Contact y

our fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can make recommendations for additives to use and for the pr

oper level of treatment.

Distillation

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

Classiﬁ

Diesel engines have the ability to burn a wide variety of fuels groups: Ref to table 7

Table 7

Fuel Groups Classiﬁcation

Group 1 Preferred fuels Full life of the

Group 2

Group 3

Group 4

rbons can affect the characteristics of

cation of the Fuels

. These fuels are divided into four general

Product

Permissible fuels with an appropriate fuel additive

Biodiesel

These fuels MAY cause reduced engine life and performance

These f WILL cause reduced engin performance

uels

elifeand

Page 53

SEBU8119-02 53

Maintenance Section

Reﬁll Capacities

Group 1 Speciﬁc

This group of fuel speciﬁcations is considered acceptable:

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

•

3, and 4

“BS2869 Class A2” Off-Highway Gas Oil Red

•

Diesel

“ASTM D975”, Class 1D , and Class 2D

•

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

•

This grade of fuel must meet the minimum lubricity requirement

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

•

that meets th

6. This blend is commonly known as B5.

Note: The use fuel is acceptable provided that the fuels meet the minimum requirements that are stated in table 6. The lubricity o diameter of 0.52 mm (0.0205 inch). The lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Re methods “ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884”, the content of sulfur in LSD fuel must be below 500 P “ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884”, the content of sulfur in ULSD fuel must be below 15 PP

s that are stated in table 6.

f these fuels must not exceed wear scar

fer to “ISO 12156-1 ”. By using the test

PM 0.05%. By using the test methods

M 0.0015%.

ations (Preferred Fuels)

e requirements that are stated in table

of LSD fuel and the use of ULSD

Group 2 Speciﬁcations (Permissible Fuels)

This group of fuel speciﬁcations is considered acceptab but these fuels MAY reduce the engine life and performance.

•

“NATO F63

•

JP8

•

JP5

•

le, but only with an appropriate fuel additive,

“JP7 (MIL-T-38219)”

”

Note: These fue these fuels are used with an appropriate fuel additive. These fuels must meet the requirements that are stated in tabl for the compliance. These fuels MUST NOT exceed lubricity wear scar diameter of 0.52 mm (0.0205 inch). The fuel lubr HFRR, operated at 60 °C (140 °F). Refer to “ISO 12156-1 ”. Fuels must have minimum viscosity of

1.4 centist pump. Fuel cooling may be required in order to maintain minimum viscosity of 1.4 centistokes that is delivered t

ls are only acceptable provided that

e 6. Fuel samples should be analyzed

icity test must be performed on a

okes that is delivered to the fuel injection

o the fuel injection pump.

Group 3 Speciﬁcations (Permissible Fuels)

This group of fuel speciﬁcation must be used only with the app reduce engine life and performance.

“JIS 2203#

Note: These fuels are only acceptable provided that these fuel These fuels must meet the requirements that are stated in table 6. Fuel samples should be analyzed for the co lubricity wear scar diameter of 0.52 mm (0.0205 inch). The fuel lubricity test must be performed on a HFRR, ope 12156-1 ”. Fuels must have minimum viscosity of

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

ropriate fuel additive. This fuel WILL

1 and #2 Toyu”

s are used with an appropriate fuel additive.

mpliance. These fuels MUST NOT exceed

ratedat60°C(140°F).Referto“ISO

el cooling may be required in order to

Group 4 Biodiesel

Biodies esters of fatty acids. Biodiesel is a fuel that can be made from a variety of feedstock. The most common Methyl Ester (REM). This biodiesel is derived from rapeseed oil. Soy Methyl Ester (SME) is the most common is derived from soybean oil. Soybean oil or rapeseed oil are the primary feedstocks. These fuels are toget

el is a fuel that can be deﬁned as mono-alkyl

ly available biodiesel in europe is Rape

biodiesel in the United States. This biodiesel

her known as Fatty Acid Methyl Esters (FAME).

“Jet A1 (

•

“Jet A (ASTM D1655)”

•

“NATO F34 ”

•

ASTM D1655)”

Page 54

54 SEBU8119-02 Maintenance Section Reﬁll Capacities

Raw pressed veg use as a fuel in any concentration in compression engines. Without esteriﬁcation, these oils gel in the crankcase and compatible with many of the elastomers that are used in engines that are manufactured today. In original forms, these in compression engines. Alternate base stocks for biodiesel may include animal tallow, waste cooking oils, or a va any of the products that are listed as fuel, the oil must be esteriﬁed.

Note: Engines that are manufactured by Perkins are certiﬁed by use of the prescribed Environmental Protection fuels. Perkins does not certify engines on any other fuel. The user of the engine has the responsibility of using th the manufacturer and allowed by the EPA and other appropriate regulatory agencies.

Recommendation for the use of biodiesel

Use of FAME following conditions apply:

The FAME f

•

A maximum of 5% mixture of FAME can be used

•

in minera complies with the fuel speciﬁcation that is listed in table 6. This blend is commonly known as B5. No mixture a above 5% will lead to reduced product service life and potential failure of the fuel injection equipment.

Note: When biodiesel, or any blend of biodiesel is used, the user has the responsibility for obtaining the proper l national exemptions that are required for the use of biodiesel in any Perkins engine that is regulated by emis 14214 is acceptable. The biodiesel must be blended with an acceptable distillate diesel fuel at the maximu operational recommendations must be followed:

•

ocal exemptions, regional exemptions, and/or

sions standards. Biodiesel that meets EN

m stated percentages. However, the following

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

Conﬁr the manufacturer of the fuel ﬁlters.

change interval can be affected by the use

ces Oil Analysis also in order to determine the

m that biodiesel is acceptable for use with

etable oils are NOT acceptable for

the fuel tank. These fuels may not be

oils are not suitable for use as a fuel

riety of other feedstocks. In order to use

Agency (EPA) and European Certiﬁcation

e correct fuel that is recommended by

fuels is permissible. However, the

uel must comply with “EN14214”.

l oil diesel fuel, provided that the fuel

bove 5% is acceptable. Concentrations

Inacomparison

•

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

The compatibility of the elastomers with biodiesel

•

is being monitored. The condition of seals and hoses should

Biodiesel may pose low ambient temperature

•

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

Biodiesel has poor oxidation stability, which

•

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

Biodiesel is a fuel that can be made from a variety

•

of feedstock. The feedstock that is used can affect t characteristics of the fuel that are affected are cold ﬂow and oxidation stability. Contact your fuel supplie

Biodiesel or biodiesel blends are not recommended

•

for engi is due to poor oxidation stability. If the user is prepared to accept some risk, then limit biodiesel to a max should limit the use of biodiesel are the following: Standby Generator sets and certain emergency vehicl

Biodiesel is an excellent medium for microbial

•

conta and growth can cause corrosion in the fuel system and premature plugging of the fuel ﬁlter. The use of the effectiveness of conventional anti-microbial additives in biodiesel is not known. Consult your supp

Care must be taken in order to remove water

•

from contamination and growth. When biodiesel is compared to distillate fuels, water is naturally more like

el. The poor oxidation stability may

ems because these engines operate at

he performance of the product. Two of the

r for guidance.

nes that will operate occasionally. This

imum of B5. Examples of applications that

mination and growth. Microbial contamination

conventionalanti-microbial additives and

lier of fuel and additive for assistance.

fuel tanks. Water accelerates microbial

ly to exist in the biodiesel.

of distillate fuels to biodiesel,

r the power loss. This will help avoid

be monitored regularly.

both storage and operation. At low

may require heated fuel lines, ﬁlters,

n. Consult your biodiesel supplier for

Page 55

SEBU8119-02 55

Maintenance Section

Reﬁll Capacities

Fuel for Cold We

ather Operation

The European standard “EN590” contains climate dependant req

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

nterclimates.0,1,2,3,and4.

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

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

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

s that are below −18 °C (−0.4 °F).

In extreme cold ambient conditions, you may also use fuels th

at are listed in the table 8. These fuels are intendedtobeusedintemperaturesthatcanbeas low as −54 °C (−65.2 °F).

Table 8

Light Disti

Speciﬁcation Grade

“MIL-T-5624R”

“MIL-T-83133D”

“ASTM D1655”

(1)

The use of these fuels is acceptable with an appropriate fuel additive and the fuels must meet minimum requirements that are stated in Table 6. Fuel samples should be analyzed f or the compliance. Fuels MUST NOT exceed 0.52 mm lubricity wear scar diameter that is tested on a HFFR . The test must be performed at 60 °C. Refer to “ISO 12156-1”. Fuels must have minimum viscosity of 1.4 centistokes that is delivered to the fuel injection pump. Fuel cooling may be required in order to maintain minimum viscosity of 1.4 centistokes that is delivered to the fuel injection pump.

llate Fuels

JP-5

JP-8

Jet-A-1

(1)

Fuel Additive

Supplemental diesel fuel additives are not generally recommended.

This is due to potential damage to the fuel system or the engine. Your fuel supplier or the fuel manufacturer will add the appropriate supplementa

ldieselfueladditives.

Perkins recognizes the fact that additives may be required i

n some special circumstances. Fuel additives need to be used with caution. Contact your fuel supplier for those circumstances when fuel additiv

es are required. Y our fuel supplier can recommend the appropriate fuel additive and the correct level of treatment.

Note: For the best results, your fuel supplier should treat the fuel when additives are required. The treated fuel must me

et the requirements that are stated in

table 6.

i02753174

Fluid Recommendations (Coolant Sp eciﬁcations)

General Coolant Information

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

NOTICE If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system must be either protected to the lowest outside temperature or drained completely to prevent damage.

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

There are many other diesel fuel speciﬁcations that are published by governments and by technological societies. Usually, those speciﬁcations do not review all the requirements that are addressed in table 6. To ensure optimum engine performance, a complete fuel analysis should be obtained before engine operation. The fuel analysis should include all of the properties thatarestatedinthetable6.

NOTICE Frequently

check the speciﬁc gravity of the coolant for

proper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

Contamination of the cooling system

•

Overheating of the engine

•

Foaming of the coolant

•

Page 56

56 SEBU8119-02 Maintenance Section Reﬁll Capacities

Additives

NOTICE Never operate a regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the proper operat lems can develop without water temperature regulators.

n engine without water temperature

ing temperature. Cooling system prob-

Additives help to protect the metal surfaces of the cooling sy insufﬁcient amounts of additives enable the following conditions to occur:

Corrosion

•

stem. A lack of coolant additives or

Many engine fa system. The following problems are related to cooling system failures: Overheating, leakage of the water pump, and plu

These failures can be avoided with correct cooling system maint as important as maintenance of the fuel system and the lubrication system. Quality of the coolant is as important a oil.

Coolant is n Water, additives, and glycol.

ilures are related to the cooling

gged radiators or heat exchangers.

enance. Cooling system maintenance is

s the quality of the fuel and the lubricating

ormally composed of three elements:

Water

Water is used in the cooling system in order to transfer he

Distilled water or deionized water is recommend

DO NOT use the following types of water in cooling systems: H conditioned with salt, and sea water.

If distill use water with the properties that are listed in Table 9.

Table 9

For a water analysis, consult one of the following sources:

Local water utility company

•

Agricultural agent

•

at.

ed for use in engine cooling systems.

ard water, softened water that has been

ed water or deionized water is not available,

Acceptable Water

Property Maximum Limit

Chloride (Cl) 40 mg/L

Sulfate (SO4) 100 mg/L

Total Hardness 170 mg/L

Acidity

ids

340 mg/L

pH of 5.5 to 9.0

Tot a l S o l

Formation of m

•

Rust

•

Scale

•

Foaming of the

•

Many additives are depleted during engine operation. These additiv

Additives must be added at the correct concentration. Overconcent inhibitors to drop out-of-solution. The deposits can enable the following problems to occur:

Formation of gel compounds

•

Reduction of

•

Leakage of the water pump seal

•

Plugging of radiators, coolers, and small passages

•

ineral deposits

coolant

es must be replaced periodically.

ration of additives can cause the

heat transfer

Glycol

Glycol in the coolant helps to provide protection against the

Boiling

•

Freezing

•

Cavitation

•

For optimum performance, Perkins recommends a 1:1 mixture

Note: Use a mixture that will provide protection against the

Note: 100 percent pure glycol will freeze at a temperatu

Most conventional antifreezes use ethylene glycol. Propylene with water, ethylene and propylene glycol provide similar protection against freezing and boiling. See Tables 10 a

following conditions:

of the water pump

of a water/glycol solution.

lowest ambient temperature.

re of −23 °C (−9°F).

glycolmayalsobeused.Ina1:1mixture

nd 11.

Independent laboratory

•

Page 57

SEBU8119-02 57

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Table 10

Ethylene Glycol

Concentration Freeze Protection

50 Percent −36 °C (−33 °F)

60 Percent

−51 °C (−60 °F)

NOTICE Do not use propylene glycol in concentrations that exceed 50 percent glycol because of propylene glycol’s reduced heat transfer capability. Use ethylene glycol in conditions that require additional protection against boiling or freezing.

Table 11

Propylene Glycol

Concentration Freeze Protection

50 Percent −29 °C (−20 °F)

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

Coolant Recommendations

ELC____________________________ Extended Life Coolant

•

In stationary e

ngine applications and marine engine applications that do not require anti-boil protection or freeze protection, a mixture of SCA and water is acceptable

. Perkins recommends a six percent to eight percent concentration of SCA in those cooling systems. Distilled water or deionized water is preferred

. Water which has the recommended

properties may be used.

Table 12

Coolant Service Life

Coolant Type Service Life

Perkins ELC

Commercial Heavy-Duty

Antifreeze t

“ASTM D4985”

Perkins POWERPART

Commercial SCA and

hat meets

SCA

Water

6,000 Service Hours or

Three Years

3000 Service Hours or

Two Years

3000 Service Hours or

Two Years

3000 Service Hours or

Two Years

ELC

Perkins provides ELC for use in the following applications:

SCA___________________Supplement Coolant Additive

•

ASTM__________________________________________ American

•

Society for Testing and Materials

The following two coolants are used in Perkins diesel engines:

Preferred – Perkins ELC

Acceptable – A commercial heavy-duty antifreeze

that meets “ASTM D4985” speciﬁcations

NOTICE Do not use a commercial coolant/antifreeze that only meets the ASTM D3306 speciﬁcation. This type of coolant/antifreeze is made for light automotive applications.

Perkins recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide optimum heavy-duty performance as a antifreeze. Thisratiomaybeincreasedto1:2watertoglycolif extra freezing protection is required.

Note: A commercial heavy-duty antifreeze that meets “ASTM D4985” speciﬁcations MAY require a treatment with an SCA at the initial ﬁll. Read the label or the instructions that are provided by the OEM of the product.

Heavy-duty spark ignited gas engines

•

Heavy-duty diesel engines

•

Automotive applications

•

The anti-corrosion package for ELC is different from the anti-corrosion package for other coolants. ELC is an ethylene glycol base coolant. However, ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite. Perkins ELC has been formulated with the correct amount of these additives in order to provide superior corrosion protection for all metals in engine cooling systems.

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

ELC Concentrate is also available. ELC Concentrate canbeusedtolowerthefreezingpointto−51 °C (−60 °F) for arctic conditions.

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

Page 58

58 SEBU8119-02 Maintenance Section Reﬁll Capacities

ELC Cooling System Maintenance

NOTICE

Correct additions to the Extended Life Coolant

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

Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to follow the re tem components life unless appropriate corrective action is performed.

In order to maintain the correct balance between the antifreeze and the additives, you must maintain the recommended concentration of ELC. Lowering the proportion of antifreeze lowers the proportion of additive. This will lower the ability of the coolant to protect the system from pitting, from cavitation, from erosion, and from deposits.

Do not use a conventional coolant to top-off a cooling system tha

Do not use standard supplemental coolant additive (SCA).

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

commendations can reduce cooling sys-

NOTICE

tisﬁlled with Extended Life Coolant (ELC).

rs.

ELC Cooling System Cleaning

Note: If th

cleaning agents are not required to be used at the speciﬁed coolant change interval. Cleaning agents ar contaminated by the addition of some other type of coolant or by cooling system damage.

e cooling system is already using ELC,

e only required if the system has been

Care must be tak contained during performance of inspection, maintenance, testing, adjusting and the repair of the product. Be pr containers before opening any compartment or disassembling any component containing ﬂuids.

Dispose of all ﬂuids according to local regulations and mandates.

1. Drain the cool

2. Dispose of the coolant according to local

regulations

3. Flush the system with clean water in order to remove any de

4. Use Perkins cleaner to clean the system. Follow the instruct

5. Drain the cleaner into a suitable container. Flush the cooling

6. Fill the cooling system with clean water and operate the 49° to 66°C (120° to 150°F).

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

To avoid damage to the cooling system, make sure to completely ﬂush the cooling system with clear water. Continue t cleaning agent are gone.

7. Drain the c and ﬂushthecoolingsystemwithcleanwater.

r incomplete ﬂushing of the cooling system

o ﬂush the system until all the signs of the

en to ensure that all ﬂuids are

epared to collect the ﬂuid with suitable

ant into a suitable container.

bris.

ion on the label.

system with clean water.

engine until the engine is warmed to

NOTICE

ooling system into a suitable container

Clean water is the only cleaning agent that is required when ELC is drained from the cooling system.

Before the cooling system is ﬁlled, the heater control (if equipped) must be set to the hot position. Refer to the OE the cooling system is drained and the cooling system is reﬁlled, operate the engine until the coolant level reaches until the coolant level stabilizes. As needed, add thecoolantmixtureinordertoﬁll the system to the speciﬁ

M in order to set the heater control. After

the normal operating temperature and

ed level.

Changing to Perkins ELC

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

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

8. Repeat St completely clean.

9. Fill the c ELC.

ooling system cleaner must be thoroughly

he cleaner may also corrode the cooling

eps6and7untilthesystemis

oolingsystemwiththePerkinsPremixed

Page 59

SEBU8119-02 59

Maintenance Section

Reﬁll Capacities

ELC Cooling Sys

tem Cont amination

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

ELC cooling systems can withstand contamination to a maximum of ten percent of conventional heavy-duty antifreeze or SCA. If the contamination exceeds ten percent of the total system capacity, perform ONE of the following procedures:

Drain the cooling system into a suitable container.

•

Dispose of the coolant according to local regulations. Flush the system with clean water. Fill the system with the Perkins ELC.

Drain a portion of the cooling system into a suitable

•

container according to local regulations. Then, ﬁll the cooling system with premixed ELC. This should lower the contamination to less than 10 percent.

Maintain the system as a conventional Heavy-Duty

•

Coolant. Treat the system with an SCA. Change the coolant at the interval that is recommended for the conventional Heavy-Duty Coolant.

Commercial Heavy-Duty Antifreeze and SCA

NOTICE Commercial Heavy-Duty Coolant which contains Amine as pa not be used.

Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the correct operating temperature. Cooling system problems can develop without water temperature regulators.

Check the antifreeze (glycol concentration) in order to ensure adequate protection against boiling or freezing. Perkins recommends the use of a refractometer for checking the glycol concentration.

Perkins engine cooling systems should be tested at 500 hour intervals for the concentration of SCA.

Additions of SCA are based on the results of the test. An SCA that is liquid may be needed at 500 hour intervals.

rt of the corrision protection system must

NOTICE

Refer to Table 1

3 for part numbers and for quantities

of SCA.

Table 13

Perkins Liquid SCA

Part Number

21825735 10

Quantity

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

Commercial heavy-duty antifreeze that meets “ASTM D4985” speciﬁcations MAY require an addition of SCA at the initial ﬁll. Read the label or the instructions that are provided by the OEM of the product.

Use the equation that is in Table 14 to determine the amount of Perkins SCA that is required when the cooling system is initially ﬁlled.

Table 14

Equation For Adding The SCA To The Heavy-Duty

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Coolant At The Initial Fill

V×0.045=X

Table 15 is an example for using the equation that is in Table 14.

Table 15

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant At The Initial Fill

Total Volum e

of the Cooling

System (V)

15 L (4 US gal)

Multiplication

Factor

×0.045

Amount of

SCA that is

Required (X)

0.7 L (24 oz)

Adding The SCA to The Heavy-Duty Coolant For Maintenance

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

Test the antifreeze periodically for the concentration of SCA. For the interval, refer to the Operation and Maint Schedule” (Maintenance Section). Test the concentration of SCA.

Additions of SCA are based on the results of the test. The size of the cooling system determines the amount of

enance Manual, “Maintenance Interval

SCA that is needed.

Page 60

60 SEBU8119-02 Maintenance Section Reﬁll Capacities

Use the equatio amount of Perkins SCA that is required, if necessary:

Table 16

Equation For Adding The SCA To The Heavy-Duty

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Table17isanexampleforusingtheequationthat is in Table 16.

Table 17

Example Of The

The Heavy-Duty Coolant For Maintenance

Total Vol u m e

of the Cooling

System (V)

15 L (4 US gal)

n that is in Table 16 to determine the

Coolant For Maintenance

V × 0.014 = X

Equation For Adding The SCA To

Multiplication

Factor

× 0.014

Amount of

SCA that is

Required (X)

0.2 L (7 oz)

Cleaning the System of Heavy-Duty Antifreeze

EMA Guidelines

The “Engine Manufacturers Association Recommended G recognized by Perkins. For detailed information about this guideline, see the latest edition of EMA publication

, “EMA DHD -1”.

uideline on Diesel Engine Oil” is

API Licensing

The Engine Oil Licensing and Certiﬁcation System by the American Petroleum Institute (API) is recognized by Perkins. F system, see the latest edition of the “API publication No. 1509”. Engine oils that bear the API symbol are authorized b

or detailed information about this

yAPI.

Perkins cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion. Perkins cooling system cleaners dissolve mineral scale, corrosion products, light oil contamination and sludge.

Clean the cooling system after used coolant is

•

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

Clean the cooling system whenever the coolant is

•

contaminated or whenever the coolant is foaming.

i02663093

Fluid Recommendations

General Lu

Because of government regulations regarding the certiﬁca the lubricant recommendations must be followed.

•

tion of exhaust emissions from the engine,

EMA_____

bricant Infor mation

Engine Manufacturers Association

_______

Illustration 26

Typical API symbol

g00546535

Terminology

Certain abbreviations follow the nomenclature of “SAE J754”. Some classiﬁcations follow “SAE J183” abbreviations, and some classiﬁcations follow the “EMA Recommended Guideline on Diesel Engine Oil”.InadditiontoPerkinsdeﬁnitions, there are other deﬁnitions that will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in this publication, “Fluid Recommendations/Engine Oil” topic (Maintenance Section).

Engine Oil

Commercial Oils

NOTICE

For appl

ications above 168 kWCI-4 oil must be used.

API_____________________ American Petroleum Institute

•

SAE___________________________________________ Society Of

•

Automotive Engineers Inc.

Page 61

SEBU8119-02 61

Maintenance Section

Reﬁll Capacities

Table 18

API Classiﬁcations for the 1106D Industrial Engine

Engine Power Oil

Speciﬁcation

Less than 168 kW (225 hp)

More than 168 kW (225 hp)

Less than 168 kW (225 hp)

CH-4/CI-4

CI-4 500 Hours

CG-4

Maintenance Interval

500 Hours

250 Hours

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:

API____________________________________________ CH-4 CI-4

•

In order to make the correct choice of a commercial oil, refer to the following explanations:

EMA DHD-1 – The EMA has developed lubricant recommendations as an alternative to the API oil classiﬁcation system. DHD-1 is a Recommended Guideline that deﬁnes a level of oil performance for these types of diesel engines: high speed, four stroke cycle, heavy-duty, and light duty. DHD-1 oils may be used in Perkins engines when the following oils are recommended: API CH-4 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 diesel engines that are operating in many applications. The tests and the test limits that are used to deﬁne DHD-1 are similar to the new API CH-4 classiﬁcation. Therefore, these oils will also meet the requirements for diesel engines that require low emissions. DHD-1 oils are designed to control the harmful effects of soot with improved wear resistance andimprovedresistancetopluggingoftheoilﬁlter. These oils will also provide superior piston deposit control for engines with either two-piece steel pistons or aluminum pistons.

All DHD-1 oils m

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

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

mmercial oil formulations.

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

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

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

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

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

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

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

rings, valve train wear, viscosity control, and corrosion.

Three new

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

t (piston deposit) also measures the control of oil consumption. A second test is conducted with moderate oil soot. The second test measures

lowing criteria: wear of piston rings, wear of

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

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

high le 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

ate high soot. The oils also have improved

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

num pistons (single piece). Oil performance is

alumi 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

ecommended for use in extended oil change

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

ributor has speciﬁc guidelines for optimizing oil

dist change intervals.

Page 62

62 SEBU8119-02 Maintenance Section Reﬁll Capacities

Some commercia

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

ndition of the oil and perform a wear

metal analysis.

NOTICE

Failuretofol

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

Total Bas e Nu

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

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

te fuel, the minimum TBN of the new oil

rdless of fuel sulfur level. Illustration 27

NOTICE

Operating Dire

ct Injection (DI) diesel engines with fuel sulphur levels over 0.5 percent will require shortened oil change intervals in order to help maintain adequate wear protecti

Table 19

Percentage of Sulfur in the fuel

Lower than 0.5 Normal

0.5to1.0

Greater than 1.0 0.50 of normal

on.

Oil change interval

0.75 of normal

Lubricant Viscosity Recommendations for Direct Injection (DI) Diesel Engines

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

Refer to Table 20 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.

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 perc ent of

the original TBN.

g00799818

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

Choose an oil with the highest TBN that meets one

•

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

Reduce the oil change interval. Base the oil

•

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

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

Refer to Table 20 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

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

Table 20

Engine Oil Viscosity

Ambient TemperatureEMA LRG-1

API CH-4

Viscosity Grade

SAE 0W20 −40 °C (−40 °F) 10 °C (50 °F)

SAE 0W30 −40 °C (−40 °F) 30 °C (86 °F)

SAE 0W40 −40 °C (−40°F) 40°C(104°F)

SAE 5W30 −30 °C (−22 °F) 30 °C (86 °F)

SAE 5W40 −30 °C (−22

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

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

Minimum Maximum

°F)

40 °C (104 °

Synthetic Base Stock Oils

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

Page 63

SEBU8119-02 63

Maintenance Section

Reﬁll Capacities

Synthetic base conventional oils in the following two areas:

Synthetic bas

•

temperatures especially in arctic conditions.

Synthetic bas

•

stability especially at high operating temperatures.

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

Re-reﬁned Ba

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

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

oils generally perform better than

eoilshaveimprovedﬂow at low

eoilshaveimprovedoxidation

c base oils have performance

the oil change intervals for any type of

se Stock Oils

s engines if these oils meet the

yinﬁnished oil or in a combination with new

rers also allow the use of re-reﬁned base

s that is used to make re-reﬁned base

sed oil. The process that is used to

Filtering is adequate for the production of

Aftermarket Oi

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

There are no i the performance or the compatibility of aftermarket additives in ﬁnished oil. Aftermarket additives may not be compa package, which could lower the performance of the ﬁnished oil. The aftermarket additive could fail to mix with the in the crankcase. Perkins discourages the use of aftermarket additives in ﬁnished oils.

To achieve the best performance from a Perkins engine, conform to the following guidelines:

Select the correct oil, or a commercial oil that meets

•

the “EMA Recommended Guideline on Diesel Engine Oi

See the appropriate “Lubricant Viscosities” table in

•

order to ﬁ engine.

At the spe

•

new oil and install a new oil ﬁlter.

l” or the recommended API classiﬁcation.

nd the correct oil viscosity grade for your

l Additives

il. It is not necessary to use aftermarket

consist of base oils and of commercial

provide ﬁnished oils with performance

ndustry standard tests that evaluate

tible with the ﬁnished oil’s additive

ﬁnished oil. This could produce sludge

ciﬁed interval, service the engine. Use

Lubrican

When an engine is started and an engine is operated in ambien multigrade oils that are capable of ﬂowing in low temperatures.

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

When an engine is started and operated in ambient temperatures below −30 °C (−22 °F), use a synthetic base sto or with a 5W viscosity grade. Use an oil with a pour point that is lower than −50 °C (−58 °F).

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

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

ts for Cold Weather

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

ck multigrade oil with an 0W viscosity grade

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

Perform m

•

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

aintenance at the intervals that are

Oil analysis

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

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

The Wea

•

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

inesmaybeequippedwithanoilsampling

s will complement the preventive maintenance

nalysis is a diagnostic tool that is used to

h the use of the oil analysis. The oil analysis

r Rate Analysis monitors the wear of the

se in the rate of engine wear metal in the

Page 64

64 SEBU8119-02 Maintenance Section Reﬁll Capacities

Tests are condu

•

contamination of the oil by water, glycol or fuel.

The Oil Condit

•

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

cted in order to detect

ion Analysis determines the loss of

f the used oil sample. This analysis

echnicians to verify the performance

Page 65

SEBU8119-02 65

Maintenance Section

Maintenance Interval Schedule

i02666635

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 68

Battery or Battery Cable - Disconnect .................. 69

Engine - Clean ...................................................... 7

Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 76

Engine Air Clea

Inspect/Replace .................................................. 78

Engine Oil Sample - Obtain .................................. 80

Fuel System - Pr

Severe Service Application - Check ..................... 95

Daily

Cooling System Coolant Level - Check ................ 73

Driven Equipment - Check .................................... 75

Engine Air Clea

Engine Air Precleaner - Check/Clean ................... 79

Engine Oil Level - Check ...................................... 80

Fuel System Prim

Drain ................................................................... 86

Walk-Around Inspection ........................................ 97

ner Element (Single Element) -

ime ............................................. 85

ner Service Indicator - Inspect ..... 79

ary Filter/Water Separator -

Fuel System Pri

Element - Replace .............................................. 87

Fuel System Secondary Filter - Replace .............. 91

Radiator - Clea

mary Filter (Water Separator)

n .................................................... 95

Every 1000 Service Hours

Engine Valve L

Water Pump - Inspect ........................................... 98

Every 2000 Service Hours

Aftercooler Core - Inspect ..................................... 66

Alternator - Inspect ............................................... 67

Belt Tensioner

Engine Mounts - Inspect ....................................... 80

Starting Motor - Inspect ........................................ 96

Turbocharger - I

ash - Inspect/Adjust ...................... 83

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

nspect .......................................... 96

Every 3000 Service Hours

Alternator and

Fan Belts - Replace ....................... 67

Every 3000 Service Hours or 2 Years

Cooling System

Change ............................................................... 70

Coolant (Commercial Heavy-Duty) -

Every 4000 Service Hours

Every Week

Alternator and Fan Belts - Inspect ........................ 67

Hoses and Clamps

- Inspect/Replace .................. 94

Every 50 Service Hours or Weekly

Fuel Tank Water a

nd Sediment - Drain ................. 93

Every 250 Service Hours

Engine Oil and Fi

lter - Change ............................. 81

Initial 500 Service Hours

Engine Valve Las

h - Inspect/Adjust ...................... 83

Every 500 Service Hours

Fan Clearance - C

heck ......................................... 84

Every 500 Service Hours or 1 Year

Battery Electr Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 74

Crankcase Breat Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 76

Engine Air Clean

Inspect/Replace .................................................. 78

Engine Oil and Filter - Change ............................. 81

olyte Level - Check .......................... 68

her (Canister) - Replace ............. 75

er Element (Single Element) -

Aftercooler Core - Clean/Test ............................... 66

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 71

Commissioning

Fan Clearance - Check ......................................... 84

Page 66

66 SEBU8119-02 Maintenance Section Aftercooler Core - Clean/Test

i02322260

Aftercooler Core - Clean /Test

1. Remove the core

for the correct procedure.

2. Turn the after

remove debris.

Personal injury can result from air pressure.

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

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

3. Pressurized air is the preferred method for

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

. Refer to the OEM information

cooler core upside-down in order to

ry can result without following prop-

ection of the fan’s air ﬂow. Hold the

llel with the tubes. This will remove

Personal injury can result from air pressure.

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

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

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

the reverse direction of the normal ﬂow.

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

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

11. After cleaning, start the engine and accelerate theenginetohighidlerpm.Thiswillhelpinthe removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.

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 o f cleaner.

5. Back ﬂush the core with a suitable cleaner.

6. Steam clea

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

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

d water may also be used for cleaning.

ed water in order to soften mud. Clean

NOTICE

ore. A high concentration of caustic cleaner

n the core in order to remove any

Aftercooler C ore - Inspect

Note: Adju

the effects of the operating environment.

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

For air-to-air aftercoolers, use the same methods that are used for cleaning radiators.

Personal

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

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

st the frequency of cleaning according to

e aftercooler for these items: damaged ﬁns,

injury can result from air pressure.

ure. When using pressure air, wear a pro-

ir pressure at the nozzle must be less

Page 67

SEBU8119-02 67

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

ator and Fan Belts -

Inspect

NOTICE 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.

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 68

68 SEBU8119-02 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 ba tteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.

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

1. Switch the engine to the OFF position. Remove

all electrical loads.

2. Turn off any battery chargers. Disconnect any

battery chargers.

3. The NEGATIVE “-” cable connects the NEGATIVE

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

4. The POSITIVE “+” cable connects the POSITIVE

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

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 Electrolyte Level Check

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

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

1. Remove the ﬁller caps. Maintain the electrolyte

level to the “FULL” mark on the ba ttery.

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

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

3. Install the caps.

4. Keep the batteries clean.

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

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

•

and 1 L (1 qt) of clean water.

Use a solution of ammonium hydroxide.

•

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 69

SEBU8119-02 69

Maintenance Section

Battery or Battery Cable - Disconnect

i02323088

Battery or Battery Cable Disconnect

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

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

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

ignition sw and remove the key and all electrical loads.

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

the battery cover in place. The bat-

personal injury.

itch (if equipped) to the OFF position

the negative battery terminal. Ensure

must be disconnected.

i02761999

Belt Tensioner - Inspect

3. Remove the positive connection.

4. Clean all disconnected connection and battery

terminals.

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

6. Ta p e t h e c prevent accidental starting.

7. Proceed w

8. In order to connect the battery, connect the

positive

urfaces are bright or shiny. DO NOT

. Coat the clamps and the terminals with

able connections in order to help

ith necessary system repairs.

connection before the negative connector.

tion 29

Illustra

Typical example

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

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

Install “Alternator Belt - Remove and Install”.

t the roller on the tensioner rotates freely.

ller for damage. Ensure that the guide roller

the belt. Refer to Disassembly and Assembly,

g01382522

Page 70

70 SEBU8119-02 Maintenance Section Cooling System Coolant (Commercial Heavy-Duty) - Change

i02238072

Cooling System Coo lant (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.

•

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.

s clean from contaminants.

fe.

Drain

Illustration 30

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

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

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.

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.

Page 71

SEBU8119-02 71

Maintenance Section

Cooling System Coolant (ELC) - Change

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

5. Stop the engin 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 d clean water.

e engine at low idle until the

e and allow the engine to cool.

cap. Open the drain cock or remove

rain. Flush the cooling system with

Fill

1. Close the dra

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

Do not ﬁll the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

2. Fill the coo 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.

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

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

, use a suitable pressurizing pump

does not retain the correct pressure,

ine. Inspect the cooling system for

i02238084

Cooling System 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.

Dispose of mandates.

Keep all parts clean from contaminants.

ormance of inspection, maintenance, test-

partment or disassembling any compo-

all ﬂuids according to Local regulations and

NOTICE

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

Illustration 31

Filler cap

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.

g00103639

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

ore the recommended maintenance

overheats frequently.

ure regulator after the cooling system has

s, if necessary.

Page 72

72 SEBU8119-02 Maintenance Section Cooling System Coolant (ELC) - Change

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. Loose n the cooling system

eve any pressure. Remove the cooling

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 ﬁ ller 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

Illustration 32

Typical examp le

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.

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

g01144180

Fill

1. Close the dr

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 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.

ain cock or install the drain plug on the

NOTICE

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

Page 73

SEBU8119-02 73

Maintenance Section

Cooling System Coolant Level - Check

2. Loosen ﬁller cap slowly in order to relieve any

pressure. Remove the ﬁller cap.

3. Pour the correct coolant mixture into the tank.

Illustration 33

Filler cap

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

g00103639

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

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

i02335378

Cooling S ystem Coolant Level

- Check

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.

tion 34

Illustra

4. Clean ﬁller cap and the receptacle. Reinstall the ﬁller cap

Note: The coolant will expand as the coolant heats up during volume will be forced into the coolant recovery tank during engine operation. When the engine is stopped and cool

Engines

and inspect the cooling system for leaks.

normal engine operation. The additional

, the coolant will return to the engine.

Without a Coolant

g00103639

Recovery Tank

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

Page 74

74 SEBU8119-02 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i02335389

Cooling System Supplemental Coolant Addit

ive (SCA) -

Test/Add

Cooling system coolan t additive contains alkali. To help prevent personal injury, avoid c ontact with the skin and the eyes. Do not drink cooling system

Illustration 35

Cooling system ﬁller cap

g00285520

coolant additive.

Test for SCA Concentration

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

1. Remove the cooling system ﬁller cap slowly in

order to rel

2. Maintain the coolant level within 13 mm (0.5 inch) of the bott equipped with a sight glass, maintain the coolant level to the correct level in the sight glass.

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

4. Inspect the cooling system for leaks.

ine and wait until the cooling system

ieve pressure.

om of the ﬁller pipe. If the engine is

and install a new ﬁller cap. If the gasket

is stamped on the face of the ﬁller cap. If

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 t he 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-

Page 75

SEBU8119-02 75

Maintenance Section

Crankcase Breather (Canister) - Replace

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. Add the correct amount of SCA. Refer to the 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

i02788266

Crankcase Breather (C anister)

- 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.

Illustration 36

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

g01392831

i02151646

Driven Equipmen t - Check

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

Inspection

•

Adjustment

•

Lubrication

•

Other maintenance recommendations

•

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

Page 76

76 SEBU8119-02 Maintenance Section Engine - Clean

i01909392

Engine - Clean

Personal injury or death can result from high voltage.

Moisture can create paths of electrical conductivity.

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

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

Failure to protect some engine components from washing may make your engine warranty invalid. Allow t he 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

•

NOTICE

ine to cool for one hour before washing

aning of the engine is recommended.

i02334355

Engine Air Cleaner Element (Dual Element

Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet.

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

Servicing the Air Cleaner Elements

Note: The air ﬁlter system may not have been

provided by Perkins. The procedure that follows is for a typic information for the correct procedure.

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

Check the pr

•

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

al air ﬁlter system. Refer to the OEM

aner element becomes plugged, the air

. Refer to the OEM information for the

ecleaner (if equipped) and the dust

) - Clean /Replace

NOTICE

Maximum heat transfer characteristics

•

Ease of main

•

Note: Cautionmustbeusedinordertoprevent electrical excessive water when the engine is cleaned. Pressure washers and steam cleaners should not be directed 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.

tenance

components from being damaged by

any electrical connectors or the junction of

otect the fuel injection pump from ﬂuids

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.

regardless of the number of cleanings.

ements. Before installation, the air cleaner

l of the air cleaner element for damage.

Dual Element Air Cleaners

The dual e cleaner element and a secondary air cleaner element.

lement air cleaner contains a primary air

Page 77

SEBU8119-02 77

Maintenance Section

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

The primary air

cleaner element can be used up to six times if the element is properly cleaned and properly inspected. The primary air cleaner element should be repl

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

The secondary air cleaner element is not serviceable. Refer to the OEM information for instructions in order to replace th

e secondary air cleaner element.

When the engine is operating in environments that are dusty or d

irty, air cleaner elements may require

more frequent replacement.

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.

Illustration 37

(1) Cov er (2) Primary air cleaner element (3) Secondary air cleaner element (4) Air inlet

1. Remove the

cover. R emove the primary air

g0073643

cleaner element.

2. The second

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

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

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

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

5. Remove the tapefrom the air inlet. Install the secondary air cleaner element. Install a primary air clean

er element that is new or cleaned.

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

•

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.

Page 78

78 SEBU8119-02 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace

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.

Pressurizedaircanbeusedtocleanprimaryair 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.

Note: Refer to “

Elements”.

Inspecting th

Inspecting the Primary Air Cleaner

e Primary Air Cleaner

Elements

Illustration 39

Inspect the Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air cleaner element. 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

clean, dry primary air cleaner element.

tate the primary air cleaner element.

hat may show through the ﬁlter material. If it

ement that has the same part number.

g00281693

Illustration 38

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

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

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

g00281692

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.

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

Engine Ai

and/or holes in the ﬁlter material. Do not

er elements.

i02152042

r C lean er Element (Single Element) Inspect/Replace

Refer to Air Cleaner Service Indicator-Inspect”.

Operation and Maintenance Manual, “Engine

NOTICE

Page 79

SEBU8119-02 79

Maintenance Section

Engine Air Cleaner Service Indicator - Inspect

Test the Service Indicator

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

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.

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.

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

Illustration 40

Typical service indicator

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

The yellow diaphragm enters the red zone.

•

The red piston locks in the visible position.

•

g00103777

Illustration 41

Typical example

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

Remove wing nut (1) and cover (2). Check for an accumula body, if necessary.

After cle wing nut (1).

Note: Whe applications, more frequent cleaning is required.

tion of dirt and debris in body (3). Clean the

aning the precleaner, install cover (2) and

n the engine is operated in dusty

g002870

Page 80

80 SEBU8119-02 Maintenance Section Engine Mounts - Inspect

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 correct bolt t 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

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 ﬁ ller 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

Engine Oil Level - Check

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

Illustration 42

(Y) “Min” mark. (X) “Max” mark.

Perform this maintenance with the engine stopped.

ot components can cause personal

g0116583

NOTICE

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

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

Obtain the Sample and the A nalysis

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

In order to help obtain the most accurate analysis, recordthefollowinginformationbeforeanoilsample is taken:

The date of the sample

•

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.

Engine model

•

Page 81

SEBU8119-02 81

Maintenance Section

Engine Oil and Filter - Change

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

Care must be tak during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the ﬂu 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.

Do not drain th engine is cold. As the engine lubricating oil cools, suspended waste particles settle on the bottom of the oil pan. T draining cold oil. Drain the oil pan with the engine stopped. Drain the oil pan with the oil warm. This draining me suspended in the oil to be drained properly.

id with suitable containers before open-

e engine lubricating oil when the

he waste particles are not removed with

thod allows the waste particles that are

NOTICE

en to ensure that ﬂuids are contained

NOTICE

i02761883

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

CG-4 oil ma of the engine must be less than 168 kW (225 hp). If this grade of engine oil is used a 250 hour service interval oil ﬁlter.

For more i Maintenance Manual, “Fluid Recommendations”.

Use the sa 500hoursserviceprocedureinordertochangethe engine oil and the engine oil ﬁlter.

y be used on some engines. The power

is required on the engine oil and the engine

nformation refer to this Operation and

me service procedure as the standard

i02667766

Engine Oil and Filter - Change

Failure to f cause the waste particles to be recirculated through the engine lubrication system with the new oil.

ollow this recommended procedure will

Drain the Engine Lubricating Oil

Note: Ensurethatthevesselthatwillbeusedislarge

enough to collect the waste oil.

After the engine has been run at the normal operating temperature, stop the engine. Use one of the following

methods to drain the engine oil pan:

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

the skin.

Page 82

82 SEBU8119-02 Maintenance Section Engine Oil and Filter - Change

Illustration 43

Typical examp le

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.

Use a magnet to d

ifferentiate between the ferrous metals and the nonferrous metals that are found in the oil ﬁlter element. Ferrous metals may indicate wear on the ste

el and cast iron parts of the engine.

Nonferrous metals may indicate wear on the aluminum par

ts, brass parts or bronze parts of the engine. Parts that may be affected include the following items: main bearings, rod bearings, and turbocharge

r bearings.

Due to normal wear and friction, it is not uncommon to ﬁ

nd small amounts of debris in the

oil ﬁlter.

If the engine is not equipped with a drain valve,

•

remove the oil drain plug (1) in order to allow the oil to drain. If the engine is equipped with a shallow oil pan, remove the bottom oil drain plugs from both ends of the oil pan.

After the oil has drained, the oil drain plugs should be cleaned and installed. If necessary, replace the O ring seal. Tighten the drain plug to 34 N·m (25 lb ft).

Replace the Oil F ilter

NOTICE Perkins oil ﬁlters are manufactured to Perkins speciﬁcations. Use of an oil ﬁlter that is not recommended by Perkins could result in severe damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unﬁltered oil entering the engine lubricating system. Only use oil ﬁlters recommended by Perkins.

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 excessive amount of metal debris in the oil ﬁlter may indicate early wear or a pending failure.

Illustration 44

Typical example

g01333549

3. Cleansealingsurface(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. Contaminated oil can cause accelerated wear to engine components.

5. Install the new oil ﬁlter.Spinontheoilﬁlter 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 45. This type of oil ﬁlter assembly can be drained 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 remove the oil ﬁlter and install the oil ﬁlter.

Page 83

SEBU8119-02 83

Maintenance Section

Engine Valve Lash - Inspect/Adjust

Illustration 45

Typical examp le

g01169166

Fill the Oil Pan

1. Remove the oil ﬁller cap. Refer to this

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

NOTICE If equipped with an auxilliary oil ﬁlter system or a 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.

Illustration 46

(Y) “Min” mark. (X) “Max” mar k.

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

Engine Valv

e Lash -

g01165836

i02348484

Inspect/Adjust

This maintenance is recommended by Perkins as partofalu schedule in order to help provide maximum engine life.

Only quali maintenance. Refer to the Service Manual or your authorized Perkins dealer or your Perkins distributor for the compl

brication and preventive maintenance

NOTICE

ﬁed service personel should perform this

ete valve lash adjustment procedure.

2. Start the engine and run the engine at “LOW IDLE” for two minutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil ﬁlters are ﬁlled. Inspect the oil ﬁlter for oil leaks.

3. Stop the engine and allow the oil to drain back to the oil pan for a minimum of ten minutes.

Operation of Perkins engines with incorrect valve lash can reduc component life.

Ensure th this maintenance is being performed. To help prevent possible injury, do not use the starting motor to turn t

Hot engine components can cause burns. Allow additio suring/adjusting valve lash clearance.

eengineefﬁciency, and also reduce engine

at the engine can not be started while

he ﬂywheel.

nal time for the engine to cool before mea-

Page 84

84 SEBU8119-02 Maintenance Section Fan Clearance - Check

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 o

r cold.

Refer to Systems Operation/Testing and Adjusting, “Engine Valv

e Lash - Inspect/Adjust” for more

information.

i02683336

Fan Clearance - Check

There are different types of cooling systems. Refer to the OEM for in

Ensure that the engine is stopped. Ensure that the cooling syst cover (1) and the fan (2) will require checking. The gap (A) between the edge of the cover and the tip of the fan blad positions.

formationonclearanceforthefan.

em is full. The clearance between the

e must be checked in four equally spaced

Illustration 4 7

g01348394

Page 85

SEBU8119-02 85

Maintenance Section

Fuel System - Prime

Adjustment of t (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 c

he cover will change the clearance

learance is 6 mm (0.2362 inch).

i02668315

Fuel Sy stem - Prime

Refer to the Operation and Maintenance Manual , “General Hazard Information and High Pressure Fuel Lines” before adjustments and repairs are performed.

1. Ensure that the Check that the fuel supply valve (if equipped) is in the “ON” position.

Illustration 48

typical example

fuel system is in working order.

g01333855

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:

The fuel tank is empty or the fuel tank has been

•

partially drained.

The low pressure fuel lines are disconnected.

•

A leak exists in the low pressure fuel system.

•

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.

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.

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.

The fuel ﬁlter has been replaced.

•

Hand Fuel Priming Pump

Use the following procedures in order to remove air from the fuel system:

Page 86

86 SEBU8119-02 Maintenance Section Fuel System Primary Filter/Water Separator - Drain

After the engin 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the c Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, “Fuel Injection L

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

e has stopped, you must wait for

repair is performed on the engine

ooling, lubrication or air systems.

ines - Install”.

nspection procedure in order to avoid

Electric Fuel Priming Pump

1. Ensure that the fuel system is in working order.

Check that the fuel supply valve (if equipped) is in the “ON” po

The electric fuel priming pump will operate for 90 seconds. If necessary the electric fuel priming pump can be stopped during the 90 seconds of operation, by operation of the switch.

2. Turn the keyswitch to the “RUN” position. Operate the switch for the electric priming pump. After 90 seconds of the electric fuel priming pump operation the fuel system will be primed and the electric fuel priming pump will turn off.

3. The engine should now be able to start.

sition.

NOTICE

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

e has stopped, you must wait for

repair is performed on the engine

ooling, lubrication or air systems.

ines - Install”.

nspection procedure in order to avoid

i02656272

Fuel System Primary Filter/Wa

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

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

ter Separato r - Drain

NOTICE

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.

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

t with high pressure fuel may cause ﬂuid

se inspection, maintenance and service in-

NOTICE The water separator can be under suction during normal engine 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. Cleanupa

operation. Ensure that the drain valve is

ny spilled fuel.

Page 87

SEBU8119-02 87

Maintenance Section

Fuel System Primary Filter (Water Separator) Element - Replace

Illustration 49

Typical examp le

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 ﬂuid in a safe place.

g01334411

2. Open drain (1). container.

3. Tighten drain the tube and dispose of the drained ﬂuidinasafe place.

4. Tighten vent screw to 6 N·m (53 lb in).

Allow the ﬂuidtodrainintothe

(1) by hand pressure only. Remove

i02668803

Fuel System Primary Filter (Water Sepa rator) Element Replace

Type O ne Filter

Illustration 50

Typical examp le

Note: N 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

ot all primary ﬁlters require vent screw (2).

screw (2).

g01371

846

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 ﬁ lter assembly.

tor in order to catch any fuel that might

Page 88

88 SEBU8119-02 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace

Illustration 51

Typical examp le

g01333866

3. Install a suitable tube onto the drain (1). Open the drain (1). Allow the ﬂuid to drain into the container. Remove the tube.

4. Tighten the drain (1) b y hand pressure only.

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).

Illustration 52

Typical example

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.

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”.

Page 89

SEBU8119-02 89

Maintenance Section

Fuel System Primary Filter (Water Separator) Element - Replace

Type Two Filter

Fuel leaked or spilled onto hot surfaces or electrical compon vent possible injury, turn the start switch off when changing fuel ﬁlters or water separator elements. Clean up fuel

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.

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.

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 53

Typical ex

ample

g01370515

3. Install a suitable tube onto the drain (1). Open the drain (1)

.Allowtheﬂuidtodrainintothecontainer.

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).

Page 90

90 SEBU8119-02 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace

Illustration 54

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.

Illustration 55

Typical ex

ample

g01370724

7. Use a suitable tool in order to remove the old canister

(4).

Page 91

SEBU8119-02 91

Maintenance Section

Fuel System Secondary Filter - Replace

i02690522

Fuel System Secondary Filter Replace

Type O ne Filter

Illustration 56

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).

Fuel leaked o

r spilled onto hot surfaces or electrical components can cause a ﬁre. To help prevent possible injury, turn the start switch off when changing fue

l ﬁlters or water separator elements.

Cleanupfuelspillsimmediately.

Note: Refer t

o Testing and Adjusting Manual , “Cleanliness of Fuel System Components” for detailed information on the standards of cleanlines

s 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 six drain holes in the ﬁlter. Refer to illustration 57.

10. Lubrica

te the O ring seal (7) with clean engine oil. Install the bowl onto the new canister. Tighten the bowl to 15 N·m (11 lb ft).

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”.

Illustration 57

Typical example

g01375918

Page 92

92 SEBU8119-02 Maintenance Section Fuel System Secondary Filter - Replace

After the engin

e has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or

repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the c

ooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, “Fuel Injection L

ines - Install”.

1. Ensure that the fuel supply valve (if equipped) is in

the O FF posi

tion. Place a suitable container under the fuel ﬁlter in order to catch any fuel that might spill. Clean up any spilled fuel.

Type Tw o ﬁlter

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

This fuel ﬁlter can be identiﬁed by the 12 drain holes in the ﬁlter. Refer to illustration 59.

Illustration 58

Typical examp le

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.

Illustration 59

Typical example

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”.

Page 93

SEBU8119-02 93

Maintenance Section

Fuel Tank Water and Sediment - Drain

1. Ens ure that the the OFF position. Place a suitable container under the fuel ﬁlter in order to catch any fuel that might spill. Clean u

Illustration 60

Typical examp le

fuel supply valve (if equipped) is in

p any spilled fuel.

g01333960

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.

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.

Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.

Drain the Water and the Sediment

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

Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve.

Check the fuel daily. Allow ﬁve minutes after the fuel tank has been ﬁlled before draining water and sediment from the fuel tank.

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.

Page 94

94 SEBU8119-02 Maintenance Section Hoses and Clamps - Inspect/Replace

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

Replace hoses t loose clamps.

Check for the f

End ﬁttings that are damaged or leaking

•

Outer covering that is chafed or cut

•

Exposedwiret

•

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:

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

i02349879

Hoses and Clamps Inspect/Replace

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

•

Type of hose

•

Type of ﬁtti

•

Anticipated expansion and contraction of the hose

•

Anticipated expansion and contraction of the

•

ﬁttings

ng material

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 the cooling system ﬁller cap, stop the e components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

text describes a typical method of replacing

he coolant system.

ngine and wait until the cooling system

Page 95

SEBU8119-02 95

Maintenance Section

Radiator - Clean

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 information on reﬁlling the

ling system ﬁller cap. Inspect the

cooling system ﬁller cap.

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 loosedebris.Directtheairintheoppositedirection to the fan’s air ﬂow. Hold the nozzle approximately 6 mm (0.25 inch) away from the radiator ﬁns. Slowly move the air nozzle in a direction that is parallel with the radiator tube assembly. This will remove debris that is between the tubes.

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

Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water.

If the radiator is blocked internally, refer to the OEM Manual for information regarding ﬂushing the cooling system.

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

After cleaning the radiator, start the engine. Allow the engine to operate at low idle speed for three to ﬁveminutes.Acceleratetheenginetohighidle.This will help in the removal of debris and the drying of the core. Slowly reduce the engine speed to low idle and then stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.

Inspect the ﬁns for damage. Bent ﬁns may be opened with a “comb”. Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.

i02335775

Severe Service Application Check

Severe exceeds the current published standards for that engine. Perkins maintains standards for the following engine

service is the application of an engine that

parameters:

Page 96

96 SEBU8119-02 Maintenance Section Starting Motor - Inspect

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

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

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

Ambient temperatures – The engine may be 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.

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

extended operation in extremely

e is frequently started and stopped in very

dusty, unless the equipment is cleaned

corrosive chemicals.

ls and salt can damage some components.

i02718318

Turbocharger - Inspect

A regular visual inspection of the turbocharger is recommended. If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to the turbocharger compressor wheel can cause additional damage to the pistons, the valves, and the cylinder head.

Page 97

SEBU8119-02 97

Maintenance Section

Walk-Around Inspection

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.

A visual insp 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

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.

Thepresenceof engine operation at low idle. The presence of oil may also be the result of a restriction of the line 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 th e En gine for Leaks and for Loose Connections

A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided.

For 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.

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

t, consult your Perkins dealer or your

ger - Install” for further information.

NOTICE

ved from the turbocharger for inspection

pipe from the turbocharger exhaust

of oil. Clean the interior of the pipes

bolts. Check for damage to the oil supply

sor wheel can rotate freely.

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.

emove the accumulated grease and oil. Re-

3. Check for the presence of oil. If oil is leaking from the back possibility of a failed turbocharger oil seal.

side of the compressor wheel, there is a

Ensure that the cooling system hoses are correctly

•

clamped and that the cooling system hoses are tight. C pipes.

heck for leaks. Check the condition of all

Page 98

98 SEBU8119-02 Maintenance Section Water Pump - Inspect

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

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.

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

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 h igh pressure fuel may cause ﬂuid penetrat el spray may cause a ﬁre hazard. Failure to follow these inspection, maintenance 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. Hi gh 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.

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

Water Pum

A failed water pump may cause severe engine overheating problems that could result in the following conditio

Cracks in the cylinder head

•

Apistonseizure

•

Other pot

•

ck the condition and the electrolyte level

calibrated.

i02794207

p - Inspect

ns:

ential damage to the engine

Page 99

SEBU8119-02 99

Maintenance Section

Water Pump - Inspect

Illustration 61

(1) Weep hole

g01249453

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.

Note: If engine coolant enters the engine lubricating system the lubricating oil and the engine oil ﬁlter must be replaced. This will remove any contamination that is caused by the coolant and this will prevent any irregular oil samples.

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”.

Page 100

100 SEBU8119-02 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

Perkins Engine 1106D Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual