Perkins Engine 1204E-E44TA, 1204E-E44TTA Service Manual

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Operation and Maintenance Manual

SEBU8605-01

May 2011

1204E-E44TA and 1204E-E44TTA Industrial Engines

(Engine)

MK ML (Engine)

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.

SEBU8605-01 3

Table of Contents

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

Safety Section

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

General Haz ard Information ................................... 7

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

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

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

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

High Pre ssure Fuel Lines ..................................... 13

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

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

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

Maintenance In

Warranty Sect

Warranty Information ........................................... 113

terval Schedule ............................ 80

ion

Reference Information Section

Reference Materials ............................................. 117

Index Section

Index .................................................................... 118

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

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

Product Information Section

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

Product Identiﬁcation Information ........................ 27

Operation Section

Lifting and Storage ................................................ 30

Gauges and Indicators .......................................... 34

Features and Controls .......................................... 36

Engine Diagnostics ............................................... 46

Engine Starting ..................................................... 52

Engine Operation .................................................. 55

Engine Stopping ................................................... 57

Cold Weathe r Operation ....................................... 59

Maintenance Section

Reﬁll Capacities .................................................... 63

Maintenance Recommendations .......................... 78

4 SEBU8605-01 Foreword

Foreword

Literature Information

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

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

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

Safety

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

g situations. Read and understand the basic

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

on this product.

repair

ntains safety, operation instructions,

re holder or literature storage area. Read,

ency.

ls or attachments that may be different

nt and advancement of product design

garding your engine, or this manual, please

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 min avoidances resulting from reductions in unscheduled downtime and failures.

ive maintenance program is followed, a

imize 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 maintena near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part o

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

nce schedules be reproduced and displayed

f the engine's permanent record.

utor can assist you in adjusting your

Overhaul

Opera

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

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

tion

. They assist with developing the skills and

lop as the operator gains knowledge of the

peration section is a reference for operators.

stopping the engine. This section also includes a

Maintenance

e maintenance section is a guide to engine care.

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

tervals. Items in the maintenance schedule are

in referenced to detailed instructions that follow.

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

e interval and the maintenance items in that

for th interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer

r Perkins distributor offers a variety of options

or you regarding overhaul programs. If you experience a major engine failure, there are also numerous

r failure overhaul options available. Consult with

afte your Perkins dealer or your Perkins distributor for information regarding these options.

California Proposition 65 Warning

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

th defects, and other reproductive harm. Battery

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

SEBU8605-01 5

Safety Section

Safety Messages

Safety Section

i04229669

Safety Message s

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

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

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

lacement part. Your Perkins distributor can

several speciﬁc warning signs on your

iliar with all warning signs.

g signs or replace the warning signs if

ng signs. Do not use solvents, gasoline, or

signs. The warning signs that are loosened

any warning sign that is damaged or

The Universal W positions. The warning labels are located on the rear right side of the valve mechanism cover and located on the top for t

arning label (1) is located in two

he NOx reduction system (NRS).

(1) Universal Warning

Do not operate or work on this equipment unless

ave read and understand the instructions

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

the warnings could result in serious injury

heed or death.

Illustration 1

ypical example

g01154807

6 SEBU8605-01 Safety Section Safety Messages

Illustration 2

ersal Warning

(1) Univ

(2) Han

d (High Pressure)

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

ay may cause a ﬁre hazard. Failure to fol-

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

g02406137

Illustration 3

Typical example

2382677

SEBU8605-01 7

Safety Section

General Hazard Information

Illustration 4

(2) Hand

(High Pressure )

g02406178

The warning label for the Hand (High Pressure) (2) is a

wrap around label that is installed on the

high-pressure fuel line.

Ether Warning

her warning label will be installed on the air

The et cleaner or close to the air cleaner. The location will depend on the application.

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

Illustration 5

Typical exa mple

g01154809

i03566024

General Hazard Inf ormation

Illustration 6

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. Attach the warning tags to the engine and to each operator control station. When it is appropriate, disconnect the starting controls.

Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced.

g00104545

Tampering with the engine installation or tampering

•

with the OEM supplied wiring can be dangerous. Personal injury, death and/or engine damage could result.

Vent the engine exhaust to the outside when the

•

engine is operated in an enclosed area.

8 SEBU8605-01 Safety Section General Hazard Information

If the engine is

•

secondary brake or the parking brake systems unless the vehicle is blocked or unless the vehicle is restrained

Wear a hard hat, protective glasses, and other

•

protective e

When work is performed around an engine that is

•

operating, to help prevent damage to hearing.

Do not wear l

•

on controls or on other parts of the engine.

Ensure tha

•

securedinplaceontheengine.

Never put m

•

Glass containers can break.

Use all cl

•

Report all necessary repairs.

•

Unless other instructions are provided, perform the maintenance under the following conditions:

not running, do not release the

quipment, as required.

wear protective devices for ears in order

oose clothing or jewelry that can snag

t all protective guards and all covers are

aintenance ﬂuids into glass containers.

eaning solutions with care.

For initial sta

•

engine that has been serviced, make provisions to stop the engine if an overspeed occurs. This may be accomplish and/or the air supply to the engine.

Start the eng

•

Never short across the starting motor terminals or the batteries. This could bypass the engine neutral start syste damaged.

Engine exha which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If th engine exhaust to the outside.

Cautiousl prevent spraying or splashing of pressurized ﬂuids, hold a rag over the part that is being removed.

Filler caps

•

Grease ﬁt

•

Pressure taps

•

rt-up of a new engine or for starting an

ed by shutting off the fuel supply

ine from the operator's station (cab).

m and/or the electrical system could be

ust contains products of combustion

e engine is in an enclosed area, vent the

y remove the following parts. To help

tings

The engine is stopped. Ensure that the engine can

•

not be started.

Theprotectivelocksorthecontrolsareinthe

•

applied position.

Engage the secondary brakes or parking brakes.

•

the vehicle or restrain the vehicle before

Block

•

maintenance or repairs are performed.

nnect the batteries when maintenance

Disco

•

is performed or when the electrical system is serviced. Disconnect the battery ground leads.

the leads in order to help prevent sparks.

Ta p e

Disconnect the connector for the unit injector that

•

cated on the valve cover base. This will help

is lo prevent personal injury from the high voltage to the unit injectors. Do not come in contact with the unit

ector terminals while the engine is operating.

inj

Do not attempt any repairs or any adjustments to

•

engine while the engine is operating.

the

Do not attempt any repairs that are not understood.

•

e the proper tools. Replace any equipment that

Us is damaged or repair the equipment.

Breathers

•

Drain pl

•

Use caution when cover plates are removed. Gradua bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last t relieve any spring pressure or other pressure.

Illustration 7

Wear a hard hat, protective glasses, and other

•

protective equipment, as required.

ugs

lly loosen, but do not remove the last two

wo bolts or nuts, pry the cover loose in order to

g00702020

When work is performed around an engine that is

•

operating, wear protective devices for ears in order to help prevent damage to hearing.

SEBU8605-01 9

Safety Section

General Hazard Information

Do not wear loos

•

on controls or on other parts of the engine.

Ensure that al

•

securedinplaceontheengine.

Never put mai

•

Glass containers can break.

Use all clea

•

Report all necessary repairs.

•

Unless other instructions are provided, perform the maintenance under the following conditions:

The engine is stopped. Ensure that the engine

•

cannot be started.

Disconnect the batteries when maintenance

•

is performed or when the electrical system is serviced Tape the leads in order to help prevent sparks.

Do not att

•

Use the proper tools. Replace any equipment that is damaged or repair the equipment.

. Disconnect the battery ground leads.

empt any repairs that are not understood.

e clothing or jewelry that can snag

l protective guards and all covers are

ntenance ﬂuids into glass containers.

ning solutions with care.

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

Pressurized Air and Water

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

When pressurized air and/or pressurized water is used f shoes, and eye protection. Eye protection includes goggles or a protective face shield.

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

al injury.

or cleaning, wear protective clothing, protective

r pressure for cleaning purposes must be below

Fluid Penetration

sure can be trapped in the hydraulic circuit long

Pres after the engine has been stopped. The pressure can cause hydraulic ﬂuid or items such as pipe plugs to

ape rapidly if the pressure is not relieved correctly.

esc

Do not remove any hydraulic components or parts

il pressure has been relieved or personal injury

unt may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved

personal injury may occur. Refer to the OEM

or information for any procedures that are required to relieve the hydraulic pressure.

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

Dispose of all ﬂuids according to local regulations and mandates.

Asbestos Information

Illustration 9

g00702022

10 SEBU8605-01 Safety Section Burn Prevention

Perkins replac Perkins are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. Use the follow replacement parts that contain asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos ﬁb to your health. The components that may contain asbestos ﬁbers are brake pads, brake bands, lining material, c asbestos that is used in these components is usually boundinaresinorsealedinsomeway.Normal handling i contains asbestos is generated.

If dust tha are several guidelines that should be followed:

Never use

•

Avoid brushing materials that contain asbestos.

•

Avoid grinding materials that contain asbestos.

•

ement parts that are shipped from

ing guidelines when you handle any

ers. Inhaling this dust can be hazardous

lutch plates, and some gaskets. The

s not hazardous unless airborne dust that

t may contain asbestos is present, there

compressed air for cleaning.

Dispose of Waste Properly

Illustration 10

Improperly disposing of waste can threaten the environment. Potentially harmful ﬂuids should be dispose

Always use leakproof containers when you drain ﬂuids. D drain, or into any source of water.

d of according to local regulations.

o not pour waste onto the ground, down a

g0070640

Use a wet

•

materials.

A vacuum

•

efﬁciency particulate air ﬁlter (HEPA) can also be used.

Use exhaust ventilation on permanent machining

•

jobs.

Wear an approved respirator if there is no other

•

way to control the dust.

Comply with applicable rules and regulations

•

for the work place. In the United States, use Occu (OSHA) requirements. These OSHA requirements can be found in “29 CFR 1910.1001”.

Obey environmental regulations for the disposal

•

of asbestos.

Stay away from areas that might have asbestos

•

particles in the air.

method in order to clean up asbestos

cleaner that is equipped with a high

pational Safety and Health Administration

i04224009

Burn Prevention

Do not touch any part of an operating engine system. The engine, the exhaust, and the engine aftertreatment system surface temperatures can reach temperatures of approximately 600° C (1112 ° F) under normal operating conditions.

Allow the engine system to cool before any maintenance is performed.

Relieve all pressure in the following systems, hydraulic system, lubrication system, fuel system, and the coolant system before the related items are disconnected.

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 c ause personal injury or death.

After the engine has stopped, you must wait for 10 minutes 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.

SEBU8605-01 11

Safety Section

Fire Prevention and Explosion Prevention

Allow the press the hydraulic system, in the lubrication system, or in the cooling system before any lines, ﬁttings, or related items

Induction Sys

Sulfuric Acid Burn Hazard may cause serious personal injury or death.

The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. Th and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted o for sulfuric acid. Always follow the directions for ﬁrst aid that are noted on a material safety data sheet (M

ure to be purged in the air system, in

are disconnected.

tem

greater than 15 ppm may increase the

e sulfuric acid will burn the eyes, skin

n a material safety data sheet (MSDS)

SDS) for sulfuric acid.

Batteries

Electrolyte i injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wa and connectors. Use of gloves is recommended.

s an acid. Electrolyte can cause personal

sh hands after touching the batteries

i03652933

Fire Prevention and Explosion Prevention

Coolant

When the engine is at operating temperature, the engine 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 b

Check that the coolant level after the engine has stop

Ensure that the ﬁller cap is cool before removing the ﬁlle 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

Oil

Hot oil and hot lubricating components can cause pe skin. Also, do not allow hot components to contact the skin.

coolant is hot. The coolant is also under

efore the cooling system is drained.

ped and the engine has been allowed to cool.

rcap.Theﬁller cap must be cool enough to touch

skin, the eyes, or the mouth.

rsonal injury. Do not allow hot oil to contact the

Illustration 11

All fuels, most lubricants, and some coolant mixtures are ﬂammable.

Flammable ﬂuids that are leaking or spilled onto hot surfaces or onto electrical components can cause 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 removed.

Determinewhethertheenginewillbeoperatedinan environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result.

If the application involves the presence of combustible gases, consult your Perkins dealer and/or your Perkins distributor for additional information about suitable protection devices.

Remove all ﬂammable combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any ﬂammable combustible materials or conductive materials to accumulate on the engine.

g00704000

12 SEBU8605-01 Safety Section Fire Prevention and Explosion Prevention

Store fuels and

lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any ﬂammable materials in protective containers. D

o not smoke in areas that are used for

storing ﬂammable materials.

Do not expose

theenginetoanyﬂame.

Exhaust shields (if equipped) protect hot exhaust components

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

Do not weld on lines or tanks that contain ﬂammable

ﬂuids. Do not ﬂame cut lines or tanks that contain ﬂammable ﬂ

uid. Clean any such lines or tanks thoroughly with a nonﬂammable solvent prior to welding or ﬂame cutting.

Wiring must be kept in good condition. All electrical wires must be correctly routed and securely attached. Check all

electrical 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.

Eliminate all wiring that is unattached or unnecessary. Do not us

e any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.

Illustration 12

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.

Arcing or sparking could cause a ﬁre. Secure connections, recommended wiring, and correctly

ined battery cables will help to prevent arcing

mainta or sparking.

Contact with high pressure fuel may cause ﬂuid

tration and burn hazards. High pressure fu-

pene el spray may cause a ﬁre hazard. Failure to follow these inspection, maintenance and service in-

ctions may cause personal injury or death.

stru

After the engine has stopped, you must wait for 10

utes in order to allow the fuel pressure to be

min 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

st be correctly routed. The lines and hoses must

mu have adequate support and secure clamps.

l ﬁlters and fuel ﬁlters must be correctly installed.

Oi The ﬁlter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly

anual for more information.

Illustration 13

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.

SEBU8605-01 13

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 equippe recommended cables, connections, and battery box covers when the engine is operated.

er cable connections can cause

d) must be kept on the cells. Use the

Fire Extinguisher

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

e ﬁre extinguisher and service the ﬁre

Lines, Tubes and Hoses

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

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

Replace the parts if any of the following conditions are pre

erkins distributor for replacement parts.

sent:

i02143194

Crushing Prevention and Cutting Preve

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

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

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

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

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

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

ve the guards in place until maintenance

be injured by ﬂying debris.

ntion

i04016709

Mounting and Dismounting

High pressure fuel line or lines are removed.

•

End ﬁttings are damaged or leaking.

•

coverings are chafed or cut.

Outer

•

Wires are exposed.

•

Outer coverings are ballooning.

•

ible part of the hoses are kinked.

Flex

•

Outer covers have embedded armoring.

•

End ﬁttings are displaced.

•

e sure that all clamps, guards, and heat shields

Mak are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other

ts, and excessive heat.

par

Do not climb on the engine or the engine aftertreatment. The engine and aftertreatment have not been designed with mounting or dismounting locations.

Refer to the OEM for the location of foot and hand holds for your speciﬁc application.

i03814031

h Pressure Fu el Lines

Hig

Contact with high pressure fuel may cause ﬂuid

enetration and burn hazards. High pressure fu-

p el spray may cause a ﬁre hazard. Failure to follow these inspection, maintenance and service in-

tructions may c ause personal injury or death.

14 SEBU8605-01 Safety Section High Pressure Fuel Lines

Illustration 14

(1) High (2) High (3) Hig

-pressure line

h-pressure line

-pressure line

(4) High

-pressure fuel manifold (rail)

(5) High

h-pressure line

(6) Hig

The high-pressure fuel lines are the fuel lines that are bet

ween 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

ines are different from fuel lines on other fuel

fuel l systems.

These

•

differences are because of the following items:

The high-pressure fuel lines are constantly charged

high pressure.

with

The internal pressures of the high-pressure fuel

s are higher than other types of fuel system.

line

The high-pressure fuel lines are formed to shape

then strengthened by a special process.

and

Do not step on the high-pressure fuel lines. Do not

ect the high-pressure fuel lines. Do not bend or

deﬂ strike the high-pressure fuel lines. Deformation or damage of the high-pressure fuel lines may cause a

int of weakness and potential failure.

Do not check the high-pressure fuel lines with the

gine or the starting motor in operation. After the

en engine has stopped wait 10 minutes in order to allow the fuel pressure to be purged from the high-pressure

uel lines. before any service or repair is performed.

g02067853

transfer line that is high pressure

(7) Fuel

Do not loosen the high-pressure fuel lines in order to remo

ve air from the fuel system. This procedure

is not required.

lly inspect the high-pressure fuel lines before

Visua the engine is started. This inspection should be each day.

If you inspect the engine in operation, always use the proper inspection procedure in order to avoid

d penetration hazard. Refer to Operation and

a ﬂui Maintenance Manual, “General hazard Information”.

ect the high-pressure fuel lines for damage,

Insp

•

deformation, a nick, a cut, a crease, or a dent.

ot operate the engine with a fuel leak. If there

Do n

•

is a leak, do not tighten the connection in order to stop the leak. The connection must only be

htened to the recommended torque. Refer to

tig Disassembly and Assembly, “Fuel injection lines Remove and Fuel injection lines - Install”.

If the high-pressure fuel lines are torqued correctly,

•

and the high-pressure fuel lines are leaking the

gh-pressure fuel lines must be replaced.

SEBU8605-01 15

Safety Section

Before Starting Engine

Ensure that all

•

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 repl Assembly manual, “ Fuel Injection Lines - Install”.

clips on the high-pressure fuel lines

aced. Refer to Disassembly and

i02813489

Before Starting Engine

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

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

Inspect the engine for potential hazards.

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

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

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

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

See the Service Manual for repairs and for adjustments.

i03996487

Engine Starting

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

If a warning tag is attached to the engine start switch, or to the co the controls. Consult with the person that attached the warning tag before the engine is started.

All protective guards and all protective covers must be installed if the engine must be started in order to perfor accident that is caused by parts in rotation, work around the parts carefully.

Start the engine from the operators compartment or from the engine start switch.

Always start the engine according to the procedure that is described in the Operation and Maintenance Manual Section. Knowing that the correct procedure will help to prevent major damage to the engine components. Knowin personal injury.

To ens and/or the lube oil heater (if equipped) is working correctly, check the water temperature gauge. Also, check operation.

ne exhaust contains products of combustion

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

. If the engine is started in an enclosed area,

area vent the engine exhaust to the outside.

e: The engine is equipped with a device for cold

Not

starting. If the engine will be operated in very cold conditions, then an extra cold starting aid may be

uired. Normally, the engine will be equipped with

req the correct type of starting aid for your region of operation.

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

order to improve starting. Some Perkins engines

in may have a cold starting system that is controlled by the ECM that allows a controlled ﬂow of ether into

he engine. The ECM will disconnect the glow plugs

t before the ether is introduced. This system would be installed at the factory.

jury.

ntrols DO NOT start the engine or move

m service procedures. To help prevent an

, “Engine Starting” topic in the Operation

g that the procedure will also help to prevent

ure that the jacket water heater (if equipped)

the oil temperature gauge during the heater

16 SEBU8605-01 Safety Section Engine Stopping

i02234873

Engine Stopping

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

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

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

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

e according to the procedure in

of the engine and accelerated wear of

gency Stop Button (if equipped) ONLY

stop, DO NOT start the engine until the

een overhauled.

he engine and/or shutting off the air supply

i04231629

Grounding Practices

Illustration 15

Typical exa mple

(1) Ground to the battery (2) Primary position for grounding (3) Ground to the starting motor (4) Ground to the engine block

g02407417

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 primary position for grounding.

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

Illustration 16

Typical exa mple

(5) Ground to the battery (6) Ground to the cylinder block

g02407418

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.

SEBU8605-01 17

Safety Section

Engine Electronics

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

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

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

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

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

lectrical circuit paths can result in

ction correctly, an engine-to-frame

nd to the frame.

rosion. The engine alternator must be

the alternator.

ons for the engine electronics should always

i03642610

Engine Electronics

Derate

•

Shutdown

•

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

Engine Coolant Temperature

•

Engine Oil Pressure

•

Engine Spee

•

Intake Manifold Air Temperature

•

Engine Intake Throttle Valve Fault

•

Wastegate

•

Supply Voltage to Sensors

•

Fuel Pressure in Manifold (Rail)

•

NOx Reduc

•

Engine Aftertreatment System

•

Regulator

tion System

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

Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM s ends 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.

ring with the electronic system installation

e damage.

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

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

, the monitoring system and the engine

any of the engine control systems and display

her, the two controls will provide the engine

eMonitoringSystem.

The following actions are available for engine monitoring control:

Warning

•

18 SEBU8605-01 Product Information Section Model Views

Product Information Section

Model Views

i04231649

Model View Illustrations

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

1204E-E44TTA

Illustration 17

(1) Front lifting eye (2) Crankcase breather (3) N Ox Reduction system (NRS) (4) Primary fuel ﬁlter (5) Secondary fuel ﬁlter

(6) Electronic control module (ECM) (7) Fuel priming pump (8) Oil gauge (dipstick) (9) Fuel strainer (10) Oil ﬁlter

g02409511

(11) Oil sampling valve (12) Oil ﬁller (13) High-pressure fuel pump

SEBU8605-01 19

Product Information Section

Model Views

Illustration 18

(14) Rear lifting eye (15) High-pressure turbocharger (16) Low-pressure turbocharger (17) Back pressure valve

(18) Starting motor (19) Oil drain plug (20) Exhaust outlet (21) Flywheel housing

g02409512

(22) Flywheel (23) NRS cooler

20 SEBU8605-01 Product Information Section Model Views

Illustration 19

(24) Belt (25) Air intake (26) Coolant outlet connection

(27) Thermostat housing (28) Water pum p (29) Coolant inlet connection

g02409862

(30) Crankshaft pulley (31) Belt tensioner (32) Alternator

SEBU8605-01 21

Product Information Section

Model Views

1204E-E44TA

Illustration 20

(1) Front lifting eye (2) Crankcase breather (3) NOx reduction system (NRS) (4) Secondary fuel ﬁlter

(5) Primary f u el ﬁlter (6) Fuel priming pump (7) Fuel strainer (8) Electronic control module (ECM)

g02407436

(9) Oil ﬁ lter (10) Oil sampling valve (11) High-pressure fuel pump

22 SEBU8605-01 Product Information Section Model Views

Illustration 21

(12) Rear lifting eye (13) Oil gauge (dipstick) (14) Turbocharger (15) Starting motor

(16) Oil drain valve (17) Oil drain plug (18) Back pressure valve (19) Flywheel housing

g02407536

(20) Flywheel (21) Exhaust outlet (22) NRS cooler

SEBU8605-01 23

Product Information Section

Model Views

Illustration 22

(23) Oil ﬁller (24) Air intake (25) Outlet connection for coolant (26) Thermostat housing

(27) Water pum p (28) Coolant intake connector (29) Rear lifting eye (30) Belt tensioner

g02407537

(31) Alternator (32) Belt

24 SEBU8605-01 Product Information Section Model Views

Engine Aftertreatment System

Illustration 23

Typical example

xible exhaust pipe

(1) Fle

et connection

(2) Inl

Engin

e Description

an emissions module

(3) Cle

nting cradle

(4) Mou

i04340692

Perkins has designed two versions of the 1204E industrial engine.

1204E-E44TA (MK)

•

4E-E44TTA (ML)

120

•

The 1204E-E44TA (MK) engine is equipped with a

gle turbocharger.

sin

The 1204E-E44TTA (ML) engine is equipped with

ries turbochargers. An engine that is equipped

se with series turbochargers have a low-pressure turbocharger and a high-pressure turbocharger.

g02483

let connec tion

(5) Out

Turbocharged charge cooled

•

Engine Speciﬁcations

The front end of the engine is opposite the ﬂywheel end of the engine. The left and the right sides of the

ne are determined from the ﬂywheel end. The

engi number 1 cylinder is the front cylinder.

616

The Perkins 1204E industrial engines have the following characteristics.

In-line four cylinder

•

our stroke cycle

•

SEBU8605-01 25

Product Information Section

Model Views

Electronic Engine Features

Illustration 24

(A) Exhaust valves (B) Inlet valves

Table 1

1204E-E44TA and 1204E-E44TTA Engine

Operating Range (rpm) 800 to 2200

Number of Cylinders 4 In-Line

Bore

Stroke 127 mm (4.99 inch)

Power

Aspiration

Compression Ratio

Displacement

Firing Order 1-3-4-2

Rotation (ﬂywheel end) Counterclockwise

(1)

The operating rpm is dependent on the engine rating, the

application, and the conﬁguration of the throttle.

Speciﬁcations

105 mm (

(80.46 to 147.51 hp)

(140.805 to 173.65 hp)

MK Single Turbocharged charge cooled ML Series Turbocharged charge cooled

4.4 L (268.504 cubic inch)

4.13 inch)

60 to 110 kW

105 to129.5 kW

16.5:1

g01187485

(1)

Theengineope

rating 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 syst

Engine monitoring

•

Engine speed governing

•

Control of t

•

Cold start strategy

•

Automatic air/fuel ratio control

•

Torque ri

•

Injection timing control

•

System diagnostics

•

Aftertr

•

em provides the following features:

he injection pressure

se shaping

eatment low temperature regeneration

For more information on electronic engine features, refer to

the Operation and Maintenance Manual,

“Features and Controls” topic (Operation Section).

Engine Diagn ostics

The eng that the engine systems are functioning correctly. The operator will be alerted to the condition by a “Stop or Warni horsepower and the vehicle speed may be limited. Theelectronicservicetoolmaybeusedtodisplay the di

There are three types of diagnostic codes: active, logg

Most of the diagnostic codes are logged and stored in th 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 des

ine has built-in diagnostics in order to ensure

ng” lamp. Under certain conditions, the engine

agnostic codes.

ed, and event.

e ECM. For additional information, refer to

ired engine rpm.

gine Cooling and Lubrication

The cooling system and lubrication system consists

the following components:

Gear-driven centrifugal water pump

•

26 SEBU8605-01 Product Information Section Model Views

Water temperat

•

engine coolant temperature

Gear-driven r

•

Oil cooler

•

The engine lubricating oil is supplied by a rotor type oil pump. The engine lubricating oil is cooled and the engine lubr can provide unrestricted ﬂow of lubrication oil to the engine if the oil ﬁlter element should become plugged.

Engine efﬁciency, efﬁciency of emission controls, and engine per operation and maintenance recommendations. Engine performance and efﬁciency also depend on the use of r coolants. Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for more informat

formance depend on adherence to proper

ion on maintenance items.

Aftertre

The aftertreatment system is approved for use by Perkins approved Perkins aftertreatment system must be used on a Perkins engine.

. In order to be emission-compliant only the

ure regulator which regulates the

otor type oil pump

icating oil is ﬁltered. The bypass valve

ecommended fuels, lubrication oils, and

atment System

Expected engin average power that is demanded. The average power that is demanded is based on fuel consumption of the engine over a p at full throttle and/or operating at reduced throttle settings result in a lower average power demand. Reduced hour operating time before an engine overhaul is required.

e life is generally predicted by the

eriod. Reduced hours of operation

s of operation will increase the length of

Aftermarket Products and Perkins Engines

Perkins does not warrant the quality or performance of non-Perk

When auxiliary devices, accessories, or consumables (ﬁlters, a manufacturers are used on Perkins products, the Perkins warranty is not affected simply because of such use.

However, failures that result from the installation or use of o accessories, or consumables are NOT Perkins defects. Therefore, the defects are NOT covered under th

ins ﬂuids and ﬁlters.

dditives, catalysts,) which are made by other

ther manufacturers devices,

e Perkins warranty.

Clean Emission Mo dule (CEM)

The CEM single unit, the Diesel Oxidation Catalyst DOC and the Diesel Particulate Filter DPF. The function of the CEM is the required emissions regulation for the country of operation.

Theengineexhaustisconnectedbyaﬂexible pipe to the CEM. The exhaust gases pass through the DOC in or and hydrocarbons. The exhaust gases then enter the DPF where any particulate matter soot and ash will be tr

The CEM uses a passive regeneration process to

ure that normal operation of the engine removes

ens the soot. The soot is removed at an equal rate of which the soot is captured. The ash remains in the DPF

Engine efﬁciency and maximum utilization of engine

rformance depend on the adherence to proper

pe operation and maintenance recommendations. In addition, use recommended fuels, coolants, and

bricants. Use the Operation and Maintenance

lu Manual as a guide for required engine maintenance.

comprises of two main components in a

to ensure that the engine exhaust meets

der to remove contaminants, carbon monoxide,

apped.

and must be removed at an engine overhaul.

gine Service Life

SEBU8605-01 27

Product Information Section

Product Identiﬁcation Information

i03865704

Plate Locations and Film Locations (Engine Aftertreatment System )

Illustration 25

Typical example

The module arrangement exhaust plate is installed on the mounting plate (1). The location of the arrangement plate mounting plate can alter depending on the application.

Illustration 26

Module Arrangement Exhaust Plate

g02109493

g02109488

Record the information that is on the plate. This information identiﬁes the engine aftertreatment system. This information will be required by your Perkins distributor. The information is essential in order to be emissions complaint.

28 SEBU8605-01 Product Information Section Product Identiﬁcation Information

Plate Locations and Film Locations (Engine)

i03827189

Serial Number Plate (1)

Theengineserialnumberplateislocatedonthe left side of the cylinder block to the rear of the front engine mounting.

ation 28

Illustr

Serial number plate

g02101733

i038672

Reference Num bers

Illustration 27

g02077373

Perkins engines are identiﬁed by an engine serial number.

An example of an engine number is ML*****U000001U.

*****

____________________The list number for the engine

_____________________________________The 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 information 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.

ation for the following items may be needed to

Inform order parts. Locate the information for your engine. Record the information in the appropriate space. Make a

copy of this list for a record. Keep the

information for future reference.

Record for Reference

ne Model

Engi

Engine Serial number _____________________________________

Engine Low Idle rpm ______________________________________

ine Full Load rpm

Eng

Primary Fuel Filter _________________________________________

Water Separator Element ________________________________

condary Fuel Filter Element

Lubrication Oil Filter Element ___________________________

Auxiliary Oil Filter Element _______________________________

otal Lubrication System Capacity

_______________________________________________

_____________________________________

__________________________

_____________________

Total Cooling System Capacity _______ __________________

Air Cleaner Element _______________________________________

SEBU8605-01 29

Product Information Section

Product Identiﬁcation Information

Drive Belt ____

________________________________________________

Engine Aftertreatment System

Part Number ________________________________________________

______________________________________________

Serial Numbe

Emissions C

An emission label is installed on the front gear cover.

Note: Asec the engine. If necessary, the second emission label will be installed on the application by the original equipment

i04274850

ertiﬁcation Film

ondemissionlabelwillbesuppliedwith

manufacturer.

Illustration 29

Typical example

g02443596

30 SEBU8605-01 Operation Section Lifting and Storage

Operation Section

Lifting and Storage

Product Lifting (Engine)

i04332972

Some removals r obtain correct balance and safety.

To re mov e th e e are on the engine.

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

n regarding ﬁxtures for correct engine

equire lifting the ﬁxtures in order to

ngine ONLY, use the lifting eyes that

are designed and installed for speciﬁc

olete. If alterations are made, ensure

Illustration 30

NOTICE

er bend the eyebolts and the brackets. Only load

Nev the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle

ween the supporting members and the object be-

bet comes less than 90 degrees.

en it is necessary to remove a component at an

Wh angle, only use a link bracket that is properly rated for the weight.

Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All

upporting members (chains and cables) should be

s parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.

g01097527

SEBU8605-01 31

Operation Section

Lifting and Storage

Industrial Open Power Unit

Illustration 31

Typical example

ation of f ront lifting eye

(1) Loc

ation of rear lifting eye

(2) Loc

g02488

437

32 SEBU8605-01 Operation Section Lifting and Storage

Product Lifting (Clean Emissi

on Module)

i04195469

i04084189

Product Storag e (Engine and Af

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 pr periods.

Condition for Storage

The engine The building must be kept at a constant temperature. Engines that are ﬁlled with Perkins ELC will have coolant p

−36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature and humidity.

Storage Period

eparing the engine for extended storage

must be stored in a water proof building.

rotectiontoanambienttemperatureof

tertreatment)

Illustration 32

Ensure that the correct clothing is worn, refer to this Operation and Maintenance Manual, “General Hazard Information”.

The weight of the clean emission module (CEM) when laden is approximately 50 kg (110 lb). Two suitable double looped slings are required in order to lift the CEM. Also a suitable hoist will be required in order to remove and install the assembly.

The slings must be attached to the CEM in the positions as shown in illustration 32.

Ensure that the slings only contact the body of the CEM. A test lift may be required in order to achieve the correct balance of the assembly.

Some applications may require a frame or jig in order to lift the CEM. A frame or jig must only be connected to the cradle of the CEM. Refer to the OEM for more information.

g02385036

An engin all the recommendation are adhered to.

Storag

Keep a record of the procedure that has been comple

Note: Do not store an engine that has biodiesel in the fu

1. Ensure that the engine is clean and dry.

2. Dra

e can be stored for up to 6 months provided

e Procedure

ted on the engine.

el system.

a. If the engine has been operated using biodiesel,

thesystemmustbedrainedandnewﬁlters

alled. The fuel tank will require ﬂushing.

inst

b. Fill the fuel system with an ultra low sulfur fuel.

ore information on acceptable fuels refer

For m to this Operation and Maintenance Manual, “Fluid recommendations”. Operate the engine

15 minutes in order to remove all biodiesel

for from the system.

in any water from the primary ﬁlter water

separator. Ensure that the fuel tank is full.

e engine oil will not need to be drained in

3. Th

order to store the engine. Provided the correct speciﬁcation of engine oil is used the engine

n be stored for up to 6 months. For the

ca correct speciﬁcation of engine oil refer to this Operation and Maintenance Manual, “Fluid

ecommendations”.

SEBU8605-01 33

Operation Section

Lifting and Storage

4. Remove the driv

Sealed Coolant System

Ensure that the cooling system is ﬁlled with Perkins ELC, or an antifreeze that meets “ASTM D6210” speciﬁcatio

Open C ooling System

Ensure that all cooling drain plugs have been opened. Allow the coolant to drain. Install the drain plugs. Plac The coolant system must be sealed once the vapor phase inhibitor has been introduced. The effect of the vapor phas is open to the atmosphere.

For mainte and Maintenance Manual.

Aftertre

No special procedures are required. The exhaust outlet o storing, the engine and the aftertreatment must be enclosed in a cover.

e a vapor phase inhibitor into the system.

e inhibitor will be lost if the cooling system

nance procedures ref to this Operation

atment

f the aftertreatment should be capped. Before

e belt from the engine.

Monthly Checks

The cra the spring loading on the valve train. Rotate the crankshaft more than 180 degrees. Visibly check f aftertreatment.

Ensur covered completely before storage. Log the procedure in the record for the engine.

nkshaft must be rotated in order to change

or damage or corrosion to the engine and

e that the engine and aftertreatment are

34 SEBU8605-01 Operation Section Gauges and Indicators

Gauges and Ind icators

i04220531

Gauges and Indicators

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

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

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

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

These indicator lamps can be used in two ways:

The in

•

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

The i

•

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

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

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

SAE10W40is350to450kPa(50to65psi)atrated rpm.

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

may not have the same gauges or all of

the normal operating range by observing

le changes in gauge readings indicate

he readings are within speciﬁcations.

utor for assistance.

Indicator lamps can be used as a diagnostic

dicatorlampscanbeusedtoidentifythe

ault. This system is automatically operated

ndicator lamps can be used to identify active

NOTICE

Engine Oil Pressure – 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

Typical temperature range is 82° to 94°C

(179.6° to 201.2°F). This temperature range will vary ac temperature.

A 100 kPa (14.5 psi) radiator cap must be installed on the cooli for the cooling system is 108° C (226.4° F). This temperature is measured at the outlet for the water temp temperature is regulated by the engine sensors and the engine ECM. This programming cannot be altered. A engine coolant temperature is exceeded.

If the eng reduce the engine load. If high coolant temperatures are a frequent event, perform the following procedu

1. Reduce the load and the engine rpm.

2. Determine if the engine must be shut down

immediately or if the engine can be cooled by reduci

3. Inspect the cooling system for leaks. If necessary,

consul

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

Operation at speeds exceeding high idle rpm should be kept to a minimum. Overspeeding can result in serious damage to the engine.

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

is in the “on” position.

cordingtoengineloadandtheambient

ng system. The maximum temperature

erature regulator. The engine coolant

n engine derate can occur if the maximum

ine is operating above the normal range,

res:

ng the load.

t your Perkins distributor for assistance.

Tachometer – This gauge indicates engine

speed

ismovedtothefullthrottlepositionwithout

ng at the full load rpm when the throttle control

Ammeter – This gauge indicates the

amount of charge or discharge in the

battery charging circuit. Operation of the

Fuel Level – This gauge indicates the fuel

level in the fuel tank. The fuel level gauge

operates when the “START/STOP” switch

Coolant Temperature –

(rpm). When the throttle control lever

NOTICE

SEBU8605-01 35

Operation Section

Gauges and Indicators

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

Indicator L a m

There is four indicator lamps that are available.

Shutdown Lamp

•

Intake temperature

•

Intake pressure

•

Atmospheric

•

Fuel temperature

•

pressure

Warning Lam

•

Wait to Start Lamp

•

Low Oil Pressure Lamp

•

For inform System (Table for the Indicator Lamps)” for the sequence of operation of the shutdown lamp and the warning l

The function of the wait to start lamp is automatically controll

The function of the low oil pressure lamp is controlled by the en the lamp will be illuminated. The reason for the illumination of the low-pressure lamp should be investi

All lamps will illuminate for 2 seconds in order to check t keyswitch is turned to the ON position. If any of the lamps stay illuminated, the reason for illumination should

ed at engine start-up.

gated immediately.

hat the lamps are functioning when the

be investigated immediately.

ation, refer to this manual, “Monitoring

amp.

gine ECM. If low oil pressure is detected,

Instr

In order to monitor the engine a wide verity of instr panels can contain the indicator lamps and the gauges for the application.

Also available are mini power displays and performance monitors. These displays and monitors can s information.

•

ument panels and Displays

ument panels are available. These instrument

how the operator the following engine

system conﬁguration parameters

The

The customer speciﬁed parameters

Diagnostic codes

ent codes

Coolant temperature

Oil temperature

36 SEBU8605-01 Operation Section Features and Controls

Features and Controls

i04340829

Monitoring System

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

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

dicator activates, engine shutdown may

, special precautions should be taken to

NOTICE

Programmable Options and Systems Operation

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

The engine can be programmed to the following modes:

“Warning”

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

“Derate”

The orange warning lamp will be ﬂashing. After the warning, the engine power will be derated.

The following parameters are monitored:

Coolant temperature

•

Intake manifold air temperature

•

Intake manifold air pressure

•

Oil pressure

•

Pressure in the fuel rail

•

Engine speed/timing

•

Fuel temperature

•

Atmospheric pressure (Barometric pressure)

•

The Inlet pressure and outlet pressure of the NOx

•

reduction system

Temperature of the NOx reduction system

•

Water in fuel switch

•

The amount of soot in the Diesel particulate ﬁlter

•

The engine will be derated if the engine exceeds preset operational limits. The engine derate is achieved by restricting the amount of fuel that is available for each injection. The amount of this reduction of fuel is dependent on the severity of the fault that has caused the engine derate, typically up to a limit of 50%. This reduction in fuel results in a predetermined reduction in engine power.

“Shutdown”

The orange warning lamp will be ﬂashing and the red shutdown lamp will be on solid. After the warning, the engine power will be derated. The engine will continue at the rpm of the set derate until a shutdown of the engine occurs. The engine can be restarted after a shutdown for use in an emergency.

A shutdown of the engine may occur in as little as 20 seconds. The engine can be restarted after a shutdown for use in an emergency. However, the cause of the initial shutdown may still exist. Theenginemayshutdownagaininaslittleas20 seconds.

If there is a signal for high coolant temperature, there will be a 2 second delay in order to verify the condition.

If there is a signal for low oil pressure, there will be a 2 second delay in order to verify the condition.

SEBU8605-01 37

Operation Section

Features and Controls

For informatio and the shutdown lamp, refer to this Operation and Maintenance Manual, “ Monitoring System (Table for Indicator modes, refer to Troubleshooting Guide, “Indicator Lamps” for more information on Indicator Lamps.

For more information or assistance for repairs, consult your Perkins distributor or your Perkins dealer.

n on the operation of the warning lamps

Lamps)”. For each of the programmed

38 SEBU8605-01 Operation Section Features and Controls

i04201172

Monitoring System (Table for the

Note: When in operation the amber warning lamp

has three states, solid, ﬂashing, and fast ﬂashing. The sequenc importance of the warning. Some application can have an audible warning installed.

Ensure that the engine maintenance is carried out at the correct intervals. A lack of maintenance can result in illumin intervals of maintenance, refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule”

Table 2

Warning

Lamp

On On Lamp Check When the keyswitch is moved to the

Off Off

On Solid Off

Flashing

Flashing On Engine

eistogiveavisualindicationofthe

ation of the warning lamp. For the correct

Shutdown

Lamp

Off

Indicator lamps)

Lamp State Description of the Indication Engine Status

ON position, the lamps come on for 2 seconds and the lamps will then go off.

No Faults With the engine in operation, there

Warning Level 1 warning The engine is operating normally but

Warning Level 2 warning The engine continues to be operated,

Shutdown

are no active warnings, diagnostic codes, or event codes.

Level 3 w arning If both the warning lamp and the shutdown lamp are in operation, this issue indicates one of the following conditions.

1. One or more of the shutdown values for the engine protection strategy has been exceeded.

The keyswitch is in the ON position but the engine has not yet been cranked.

The engine is operating with no detected faults.

there is one or more faults with the electronic management system for the engine.

but the level of importance of the warning has increased. Depending on the particular fault and the severity the engine may be de-rated. The engine could be damaged if continued to be operated.

The engine is either shutdown or an engine shutdown is imminent. One or more monitored engine parameters have exceeded the limit for an engine shutdown. This pattern of lamps can be caused by the detection of a serious active diagnostic code.

2. A serious active diagnostic code has been detected.

After a short time period, the engine may shut down.

SEBU8605-01 39

Operation Section

Features and Controls

i04215952

Sensors and Electrical Components (Aftertreatment)

The illustration within the section shows the typical loc components on the industrial engine. Speciﬁc engine aftertreatment systems may appear different due to the applica

ations of the sensors and other electrical

tion.

Illustration 33

(1) Temperature Sensor (2) Connec tor for Temperature Sensor (3) Soot Sensor Connection (4) Aftertreatment Identiﬁcation Module (5) Soot Sensor Connection (6) Soot Sensor

Note: The location of the soot sensor will depend on the application.

g02395776

i04238530

Sensors and Electrical Components

The illustration within the section shows the typical locations of the sensors and other electrical components on a 1204 Industrial engine. Speciﬁc engines may appear different due to the application.

40 SEBU8605-01 Operation Section Features and Controls

Illustration 34

(1) Coolant Temperature Sensor (2) Fuel Pressure Sensor (Fuel Rail

Pressure Sensor) (3) Intake Manifold Air Temperature Sensor (4) Intake Manifold Pressure Sensor (5) E lectronic Control Module (ECM) (6) Atmospheric Pressure Sensor

(Barometric Pressure Sensor)

(7) Primary Speed/Timing sensor

(Crankshaft Position Sensor) (8) Diagnostic Conn ector (9) Oil Pressure Sensor (10) Fuel Temperature Sensor (11) Solenoid for the High Pressure Fuel

Pump (12) Wastegate Regulator

g02411637

(13) Inlet Pressure Sensor for the NOx

Reduction System (NRS) (14) Outlet Pressure Sensor for the NRS (15) Control Valve for the NRS (16) Temperature Sensor for the NRS

SEBU8605-01 41

Operation Section

Features and Controls

Illustration 35

(17) Back Pressur e Valve (18) Alternator

ustration 36

Ill

(1) Coolant Temperature Sensor (2) Fuel Pressure Sensor (Fuel Rail

Pressure Sensor)

(19) Secondary Speed/Timing Sensor

(Camshaft Position Sensor)

(20) Starting Motor

(3) Intake Manifold A ir Temperature Sensor (4) Intake Manifold Pressure Sensor (5) Electronic Control Module (ECM)

g02411837

(21) Water in Fuel Sw itch (22) Oil Level Switch (if Equipped) (23) Electric P riming Pump

g02413838

42 SEBU8605-01 Operation Section Features and Controls

Illustration 37

(6) Atmospheric Pressure Sensor

(Barometric Pressure Sensor)

stration 38

Illu

(10) Fuel Temperature Sensor (11) Solenoid for the High Pressure F uel

Pump

(7) Primary Speed/Timing sensor

(Crankshaft Position Sensor)

(12) Wastegate Regulator (13) Inlet Pressure Sensor for the NOx

Reduction System (NRS)

g02413839

(8) Diagnostic C o nnector (9) Oil Pressure Sensor

g02413840

(14) Outlet Pressure Sensor for the NRS

SEBU8605-01 43

Operation Section

Features and Controls

Illustration 39

(15) Control Valve for the NRS (16) Temperature Sensor for the NRS (17) Back Pressure Valve

stration 40

Illu

(18) Alternator (19) Secondary Speed/Timing Sensor

(Camshaft Position Sensor)

(20) Starting Motor

g02414076

g02414077

44 SEBU8605-01 Operation Section Features and Controls

Illustration 41

(21) Water in Fuel Switch (22) Oil Level Switch (if Equipped) (23) Electric Priming Pump

i04372832

Engine Shutoffs and Engine 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

•

g02414506

Types and locations of the 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 is controlled by the ECM.

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

Your engine may be equipped with the following sensors or switches:

Coolant level – The low coolant level switch indicates when the coolant level is low.

The particular shutoff may need to be reset before the engine will start.

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

Be familiar with the following items:

Coolant temperature – The coolant temperature sensor indicates high jacket water coolant temperature.

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

SEBU8605-01 45

Operation Section

Features and Controls

Intake manifol

pressure sensor checks the rated pressure in the engine manifold.

Fuelrailpressure –The fuel rail pressure sensor checks for high pressure or low pressure in the fuel rail.

Engine oil pressure – The engine oil pressure sensor indi system pressure, at a set engine speed.

Engine over

overspeed setting, the alarm will be activated.

Air ﬁlter r

ﬁlter when the engine is operating.

User-Deﬁn

the engine remotely.

Water in f

in the primary fuel ﬁlter when the engine is operating.

Fuel temp

monitors the pressurized fuel in the high-pressure fuel pump.

d pressure – The intake manifold

cates when oil pressure drops below rated

speed – If the engine rpm exceeds the

estriction – The switch checks the air

ed switch – This switch can shut down

uel switch – This switch checks for water

erature – The fuel temperature sensor

i03554501

Overspeed

ECM _________

•

RPM ________________________ Revolutions Per Minute

•

An overspeed is detected by the speed/timing sensors.

Thedefaultsettingforanoverspeedis3000rpm. The ECM will cut the power to the electronic unit injectors overspeed setting. A diagnostic fault code will be logged into the ECM memory and a warning lamp will indicate a

An overspeed can be set from 2600 rpm to 3000 rpm. This sett

, until the rpm drops below 200 rpm of the

ing depends on the application.

_____________

diagnostic fault code.

Electronic Control Module

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

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

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

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

Tes

Turning the keyswitch to the ON position will check th indicator lights will be illuminated for 2 seconds after the keyswitch is operated. Replace suspect bulbs im

to operate.

t the operator when undesirable operating

NOTICE

en before the situation becomes an emergency

rrective measures are not taken within a

alarm may need to be reset.

ting

e indicator lights on the control panel. All the

mediately.

Refer to Troubleshooting, KENR9116 for more

formation.

46 SEBU8605-01 Operation Section Engine Diagnostics

Engine Diagnostics

i02651093

Self-Diagnostics

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

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

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

Logged codes represent the following items:

Intermittent problems

•

Recorded events

•

Performance history

•

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

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

i02651107

Diagnostic Lamp

A diagnostic lamp is used to indicate the existence of

active fault. Refer to Troubleshooting , “Indicator

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

he diagnostic code may be retrieved by using the

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

i04215570

Diagnostic Flash Code Retrieval

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 within3se

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

Table 3

Injector fault

Injector number 2 current out of range

Injector number 3 current out of range 113

Injector number 4 current out of range 114

Injector number 5 current out of range (6 cylinder only)

Injector number 6 current out of range (6 cylinder only)

Intake manifold air temperature sensor out of range

Engine speed sensor out of range

Engine timing offset fault

Engine operation mode selector switch erratic, intermittent, or incorrect

High air ﬁlter restriction - Warning

Atmospheric pressure sensor out of range

Throttle position sensor out of range 154

Secondary throttle position sensor out of range

Oil pressure sensor out of range

conds.

. The sequence of ﬂashes represents the

. After a two second pause, the second

eofﬂashes will identify the ﬂash code.

Flash Code Table

Description

Flash Code

111

112

115

116

133

141

143

144

151

152

155

157

(continued)

SEBU8605-01 47

Operation Section

Engine Diagnostics

(Table 3, contd)

Fuel rail pressure sensor out of range

Fuel temperature sensor out of range

Engine coolant temperature sensor out of range

Low Engine Coolant Level Shutdown

Turbo waste

Intake manifold pressure sensor out of range

Glow plug start aid relay current above normal

Diesel Particulate Filter DPF Intake temperature sensor out of range

DPFSootsensorsoutofrange

Exhaust gas recirculation temperature/pressure out of range

Exhaust gas recirculation valve control current out of range

Exhaust gas recirculation valve control voltage out of range

Exhaust gas recirculation pressure sensor out of range

Air inlet temperature sensor voltage out of range

r injection control solenoid out of

Ethe range

Idlevalidationswitch#1erratic, intermittent, or incorrect

Idlevalidationswitch#2erratic, intermittent, or incorrect

Exhaust Gas Recirculation Outlet Pressure Sensor out of range

Exhaust back pressure regulator position voltage out of range

Engine Fuel Supply Lift Pump Relay out of range

ersonality module erratic,

P intermittent, or incorrect

Machine security system module abnormal update rate

Ignition key switch loss of signal

Electrical System Voltage fault

SAE J1939 Data L ink abnormal update rate

5 Volt sensor DC power supply voltage out of range

gate drive out of range 177

159

165

168

169

197

199

224

226

227

228

229

231

232

233

245

246

247

249

253

426

429

511

514

516

(continued)

(Table 3, contd)

8 V DC Supply voltage out of range

Programmed parameter fault erratic, intermittent, or incorrect

5 Volt Sensor DC Power Supply #2 out of range

No diagnostic code detected 551

517

527

528

Refer to Troubleshooting, “Diagnostic Flash Code Cross Reference” for more information.

i01902949

Fault Logging

The system provides the capability of Fault Logging. When the Electronic Control Module (ECM) generates an active diagnostic code, the code will be logged in the memory of the ECM. The codes that have been logged by the ECM can be identiﬁed by the electronic service tool. The active codes that have been logged will be cleared when the fault has been rectiﬁed or the fault is no longer active. The following logged faults can not be cleared from the memory of the ECM without using a factory password: Overspeed, low engine oil pressure, and high engine coolant temperature.

48 SEBU8605-01 Operation Section Engine Diagnostics

i03554534

Engine Operation with A ctive Diagnostic Co

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

Note: If the there is a low oil pressure condition, the Electronic Control Module (ECM) will limit the engine power until the p within the normal range, the engine may be operated at the rated speed and load. However, maintenance should be p

The active diagnostic code should be investigated. The cause soon as possible. If the cause of the active diagnostic code is repaired and there is only one active diagnos

Operation of the engine and performance of the engine c diagnostic code that is generated. Acceleration rates may be signiﬁcantly slower. Refer to the Troubl relationship between these active diagnostic codes and engine performance.

n the speciﬁcation. Use electronic service

customer has selected “DERATE” and if

roblem is corrected. If the oil pressure is

erformed as soon as possible.

of the problem should be corrected as

tic code, the diagnostic lamp will turn off.

an be limited as a result of the active

eshooting Guide for more information on the

des

i01902995

Engine Operation with Intermittent

If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off, an intermitte 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 s and the operator should reference the appropriate information in order to identify the nature of the event. The operat have caused the lamp to light.

Low power

•

Limits of the engine speed

•

Excessive smoke, etc

•

This inf thesituation.Theinformationcanalsobeusedfor future reference. For more information on diagnostic codes, engine.

nt fault may have occurred. If a fault has

hould retrieve the logged fault codes

or should log any observation that could

ormation can be useful to help troubleshoot

refer to the Troubleshooting Guide for this

Diagnostic Codes

i04217251

Conﬁguration Parameters

The engine electronic control module (ECM) has two types of conﬁguration parameters. The system conﬁguration parameters and the customer speciﬁed parameters.

The electronic service tool is required in order to alter the conﬁguration parameters.

System Conﬁguration Parameters

System conﬁguration parameters affect the emissions of the engine or the power of the engine. System conﬁguration parameters are programmed at the factory. Normally, system conﬁguration parameters would never require changing through the life of the engine. System conﬁguration parameters must be reprogrammed if an ECM is replaced. System conﬁguration parameters do not require reprogrammed if the ECM software is changed. Factory passwords are required to change these parameters.

SEBU8605-01 49

Operation Section

Engine Diagnostics

Table 4

System Conﬁguration Parameters

Conﬁguration Parameters Record

Full Load Setting

Full Torque

Rating

Engine Serial Number

Factory Installed Aftertreatment Identiﬁcation Number

DPF Soot Loading Sensing System Conﬁguration Code

Limp Home Engine Speed Ramp Rate

ECM Software Release Date

Setting

Customer Speciﬁed Parameters

Customer speciﬁed parameters allow the engine to be conﬁgured to the exact needs of the application.

The electronic service tool is required in order to alter the customer conﬁguration parameters.

Customer parameters may be changed repeatedly as operational requirements change.

Table 5

Customer Speciﬁed Parameters

Speciﬁed Parameters Record

Low Idle Parameters

ECM Identiﬁcation Parameter

Ether Solenoid Conﬁguration

PTO and Throttle Lock Parameters

Throttle Lock Feature Installation Status

PTO Mode

Throttle Lock Engine Set Speed 1

Throttle Lock Engine Set Speed 2

Throttle Lock Increment Speed Ramp Rate

Throttle Lock Decrement Speed Ramp Rate

Throttle Lock Engine Set Speed Increment

Throttle Lock Engine Set Speed Decrement

Monitoring Mode Shutdowns

Monitoring Mode Derates

Limp Home Desired Engine Speed

Engine Acceleration Rate

Engine Speed Decelerating Ramp Rate

Coolant Level Switch

(continued)

50 SEBU8605-01 Operation Section Engine Diagnostics

(Table 5, contd)

Air Filter Restriction Switch Installation Status

Air Filter Restriction Switch Conﬁguration

System Operating Voltage Conﬁguration

Minimum Ambient Air Temperature

Maximum Ambient Air Temperature

Shutdown Enable Status

Shutdown Delay Time

Ambient Temperature Override Enable Status

Air Shutoff

Intermediate Engine Speed

Engine Fan Control

Engine Fan Type Conﬁguration

Pulley Ratio

Temperature Error Increasing Hysteresis

Temperature Error Decreasing Hysteresis

Current Ramp Rate

peed

Fan S

Top F a n S pee d

Minimum Desired Fan Speed

Solenoid Minimum Current

Solenoid Maximum Current

Solenoid Dither Frequency

Solenoid Dither Amplitude

Charge Air Cooler Outlet Temperature Input Enable

Maximum Air Flow Charge Air Cooler Outlet Temperature

Minimum Air Flow Charge Air Cooler Outlet Temperature

Coolant Temperature Input Enable Status

Maximum Air Flow Coolant Temperature

Minimum Air Flow Coolant Temperature

Transmission Oil Temperature Input Enable Status

Maximum Air Flow Transmission Oil Temperature

Minimum Air Flow Transmission Oil Temperature

Hydraulic Oil Temperature Input Enable Status

Maximum Air Flow Hydraulic Oil Temperature

Minimum Air Flow Hydraulic Oil Temperature

Auxiliary #1 Temperature Input Enable Status

Maximum Air Flow Auxiliary #1 Temperature

Minimum Air Flow Auxiliary #1 Temperature

Auxiliary #2 Temperature Input Enable Status

(continued)

SEBU8605-01 51

Operation Section

Engine Diagnostics

(Table 5, contd)

Maximum Air Flow Auxiliary #2 Temperature

Minimum Air Flow Auxiliary #2 Temperature

Reversing Feature

Reverse Operation Early Termination Enable Status

Manual Purge

Suspend Purge

Purge Cycle Interval

Purge Cycle Duration

Coolant Level Switch

Air Filter Restriction Switch Installation Status

Air Filter Restriction Switch Conﬁguration

WaterinFuelSwitchInstallationStatus

User Deﬁned Switch Installation Status

iary Temperature Sensor Installation Status

Auxil

Auxiliary Pressure Sensor Installation Status

Diesel Particulate Filter Regeneration Force/Inhibit Switch Installation

Remote Torque Speed Control Enable Status

System Operating Voltage Conﬁguration

Customer Password 1

Customer Password 2

CAN Communication Protocol Write Security

AN Communication Protocol Read Security

52 SEBU8605-01 Operation Section Engine Starting

Engine Starting

i03648917

Before Starting Engine

S/N: MK11-U

Perform the required daily maintenance and other periodic m Inspect the engine compartment. This inspection can help prevent major repairs at a later date. Refer to the Operation Interval Schedule” for more information.

Ensure th

•

supply.

Open the

•

All valves in the fuel return line must be open and fuel supply can occure if fuel lines are closed with the engine in operation.

aintenance before the engine is started.

and Maintenance Manual, “Maintenance

at the engine has an adequate fuel

fuel supply valve (if equipped).

NOTICE

lines must be open. Damage to the fuel system

i04084389

Starting th e Engine

Note: Do not ad

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

Starting the Engine

1. Disengage any equipment that is driven by the

engine.

2. Turn the keyswitch to the RUN position. Leave the keyswitchintheRUNpositionuntilthewarning light for t

Note: During the key on, the indicator lamps will be illumi operation. If any of the lamps do not illuminate, replace the bulb.

3. When the warning light for the glow plugs is

nated for 2 seconds in order to check lamp

extinguished, turn the keyswitch to the START

n in order to engage the electric starting

positio motor and crank the engine.

justtheenginespeedcontrolduring

he glow plugs is extinguished.

If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air may have entered the ﬁlter housing. Also, when fuel ﬁlters have been changed, some air pockets will be trapped in the engine. In these instances, prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information on priming the fuel system. Also, check that the fuel speciﬁcation is correct and that the fuel condition is correct. Refer to the Operation and Maintenance Manual, “Fuel Recommendations”.

Engine exhaust contains products of combustion

ich may be harmful to your health. Always start

wh and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the

tside.

Do not start the engine or move any of the controls

•

f there is a “DO NOT OPERATE” warning tag or

i similar warning tag attached to the start switch or to the controls.

Note: Th the glow plugs will change due to the temperature of the engine.

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 allo start the engine again.

4. Allo

5. Rep

e operating period of the warning light for

NOTICE

w the starting motor to cool before attempting to

w the keyswitch to return to the RUN position

after the engine starts.

eat step 2 through step 4 if the engine fails

to start.

i03570564

Cold Weather Starting

Reset all of the shutoffs or alarm components.

•

Ensure that any driven equipment has been

•

disengaged. Minimize electrical loads or remove any electrical loads.

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

SEBU8605-01 53

Operation Section

Engine Starting

Startability w

−18 °C (0 °F) from the use of a jacket water heater or extra battery capacity.

When Group 2 diesel fuel is used, the following items provide a means of minimizing starting problems and fuel prob heaters, jacket water heaters, fuel heaters, and fuel line insulation.

Use the procedure that follows for cold weather starting.

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

1. Disengage any driven equipment.

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

keyswitch in the RUN position until the warning light for

Do not engage the starting motor when ﬂywheel is turning

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

illbeimprovedattemperaturesbelow

lems in cold weather: Engine oil pan

e engine speed during start-up.

the glow plugs is extinguished.

NOTICE

. Do not start the engine under load.

ter switch or button and wait two minutes to

7. Operate the eng reach operating temperature. Check the gauges during the warm-up period.

ine at low load until a ll systems

i03663103

Starting with Jump Start Cables

Improper jump start ca ble connections can cause an explosi

Prevent sparks near the batteries. Sparks could cause vap cable ends to contact each other or the engine.

Note: If

the starting failure. Refer to Troubleshooting, “Engine Will Not Crank and Engine Cranks But Will Not Start” for furt If the engine will not start only due to the condition of the battery, either charge the battery, or start the engine cables. The condition of the battery can be rechecked after the eng

on resulting in personal injury.

ors to explode. Do not allow jump start

it is possible, ﬁrst diagnose the reason for

her information. Make any necessary repairs.

by using another battery with jump start

inehasbeenswitchedOFF.

3. When the warning light for the glow plugs is extinguished turn the keyswitch to the START

ion in order to engage the electric starting

posit motor and crank the engine.

: The operating period of the warning light for

Note

the glow plugs will change due to the temperature of the engine.

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.

Note: The engine should not be “raced” in order to speed up the warm up process.

6. Allow the engine to idle for three to ﬁve minutes, or allow the engine to idle until the water temperature

dicator begins to rise. When idling after the

in engine has started in cold weather, increase the engine rpm from 1000 to 1200 rpm. This will

rm up the engine more quickly. Maintaining

wa an elevated low idle speed for extended periods will be easier with the installation of a hand

hrottle. Allow the white smoke to disperse before

t proceeding with normal operation.

NOTICE Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for jump starting. The use of higher voltage will damage the electrical system.

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

Turn all electrical accessories OFF before attaching the jump start cables.

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

1. Turn the start switch on the stalled engine to the

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

2. Connect one positive end of the jump start cable

to the positive cable terminal of the discharged battery. Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source.

54 SEBU8605-01 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

Note: The engine ECM must be powered before the starting mo

4. Start the engine in the normal operating procedure. Refer to thi “Starting the Engine”.

5. Immediate the jump start cables in reverse order.

After jump fully recharge batteries that are severely discharged. The batteries must be replaced or charged to the proper vo is stopped. Many batteries which are considered unusable are still rechargeable. Refer to Operation and Maint Testing and Adjusting Manual, “Battery - Test”.

tor is operated or damage can occur.

starting, the alternator may not be able to

ltage with a battery charger after the engine

enance Manual, “Battery - Replace” and

ative end of the jump start cable

le to the engine block or to the

e produced by some batteries.

s Operation and Maintenance Manual,

ly after the engine is started, disconnect

i02330138

After Starting Engine

Note: In ambie

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

When the engine idles during warm-up, observe the following c

Do not check the high pressure fuel lines with the engine or t inspect the engine in operation, always use the proper inspection procedure in order to avoid a ﬂuid penet Maintenance Manual, “General hazard Information”.

Check for

•

and at one-half full rpm (no load on the engine) before operating the engine under load. This is not possible

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

•

allow th indicator begins to rise. Check all gauges during the warm-up period.

nt temperatures from 0 to 60°C

arm-up time may be required.

onditions:

he starting motor in operation. If you

ration hazard. Refer to Operation and

any ﬂuid or for any air leaks at idle rpm

in some applications.

e engine to idle until the water temperature

Note: Gauge readings should be observed and the data should be recorded frequently while the engine will help to determine normal readings for each gauge. Comparing data over time will also help detec changes in the readings should be investigated.

is operating. Comparing the data over time

t abnormal operating developments. Signiﬁcant

SEBU8605-01 55

Operation Section

Engine Operation

i03858430

Engine Operation

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

Thetimeth normal operating temperature can be less than the time taken for a walk-around inspection of the engine.

The engine can be operated at the rated rpm after the engine is started and after the engine reaches operati operating temperature sooner during a low engine speed (rpm) and during a low-power demand. This procedu at no load. The engine should reach operating temperature in a few minutes.

ation and maintenance are key factors

ce Manual are followed, costs can be

at is needed for the engine to reach

ng temperature. The engine will reach normal

re is more effective than idling the engine

Engine Operati

During normal engine operation, the operator of the engine may not exhaust system.

Passive rege by the DPF in order to remove soot from the DPF. In some applications, the engine idle speed will automatica regeneration to occur.

lly be increased in order to allow passive

on and a DPF

ice the lack of black smoke from the

neration is the process that is used

Avoid excess idling. Excessive idling causes carbon buildup, engine slobber, and soot loading of the Diesel harmful to the engine.

Gauge should be recorded frequently while the engine is operating. Comparing the data over time will help t Comparing data over time will also help detect abnormal operating developments. Signiﬁcant chan

Redu

The Diesel Particulate Filter (DPF) will reduce par any ash that is produced by the combustion in the engine. During regeneration, the soot is converted int Ash remains in the DPF.

Th particular value in order for regeneration to occur. The exhaust gas provides heat for the regeneration pr

Particulate Filter (DPF). These issues are

readings should be observed and the data

o determine normal readings for each gauge.

ges in the readings should be investigated.

ction of Particulate Emissions

ticulate emissions. The DPF collects the soot and

o a gas which is released into the atmosphere. The

e temperature of the DPF must be above a

ocess.

Passive Regeneration – Theengineprovides

ufﬁcient exhaust gas temperature for regeneration.

56 SEBU8605-01 Operation Section Engine Operation

i04018232

Fuel Conservation Practices

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

Avoid spilling fuel.

•

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

Be aware of the properties of the different fuels.

•

Use only the recommended fuels. Refer to the Operatio Recommendations”for further information.

Avoid unn

•

Shut off the engine rather than idle for long periods of time.

Observe the service indicator frequently. Keep the

•

air clea

Ensure that the turbocharger is operating correctly.

•

For mor Maintenance Manual , “Turbocharger - Inspect”

of the engine can affect the fuel

ions. Follow the recommended procedures

ds when the fuel is warmed up. The fuel

ns and Maintenance Manual, “Fuel

ecessary idling.

ner elements clean.

e information refer to this Operation and

ain a good electrical system.

Maint

•

One faulty battery cell will overwork the alternator.

ault will consume excess power and excess

This f fuel.

elt should be in good condition. Refer to the

The b

•

Systems Operation, T esting and Adjusting, “V-Belt Test” for further information.

Ensure that all of the connections of the hoses are

•

tight. The connections should not leak.

Ensure that the driven equipment is in good

•

working order.

Cold engines consume excess fuel. Utilize heat

•

from the jacket water system and the exhaust

stem, when possible. Keep cooling system

sy components clean and keep cooling system components in good repair. Never operate the

gine without water temperature regulators.

en All of these items will help maintain operating temperatures.

SEBU8605-01 57

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

Emer

gency Stopping

i03648931

After Stopping Engine

Note: Before y

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

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

After the

•

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

Check the crankcase oil level. Maintain the oil level

•

betwee the engine oil level gauge.

If the e

•

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

tenance Interval Schedule”.

“Main

ou check the engine oil, do not operate

h high pressure fuel may cause ﬂuid

nspection, maintenance and service in-

engine has stopped, you must wait for

ce or repair is performed on the engine

nd from the cooling, lubrication or air

“Fuel Injection Lines - Install”.

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

ngine is equipped with a service hour meter,

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

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

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

Fill the fuel tank in order to help prevent

•

Only use antifreeze/coolant mixtures recommended in the is in this Operation and Maintenance Manual. Failure to do so can cause engine damage.

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

•

mulation of moisture in the fuel. Do not overﬁll

accu the fuel tank.

NOTICE

Reﬁll Capacities and Recommendations topic that

Allow the engine to cool. Check the coolant level.

58 SEBU8605-01 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.

SEBU8605-01 59

Operation Section

Cold Weather Operation

i04321989

Cold Weather Operat 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 ele

•

fraying or damaged insulation.

Keep all bat

•

Fill the fuel tank at the end of each shift.

•

Check the air cleaners and the air intake daily.

•

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

Ensure that the glow plugs are in working order.

•

Refer to Tr Tes t”.

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 injur y or prope

rect speciﬁcation of engine lubricant

er parts (hoses, fan drive belts,)

ctrical wiring and connections for any

teries fully charged and warm.

oubleshooting, “Glow Plug Starting Aid-

rty damage.

The operation and maintenance of an engine in freezing temperatures is complex . This complexity 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 80° C (176° 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 down for a period and the engine can still 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.

60 SEBU8605-01 Operation Section Cold Weather Operation

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

, check the coolant often for the

Engine Block Heaters

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

Startability is improved.

•

Warm up time

•

An electric block heater can be activated once the engine is s 240 V dc. The output can be 750/1000W. Consult your Perkins dealer or your Perkins distributor for more infor

Idling th

When idling after the engine is started in cold weather, rpm. This idling will warm up the engine more quickly. Maintaining an elevated low idle speed for extended periods throttle. The engine should not be “raced” in order to speed up the warm-up process.

While the engine is idling, the application of a light load (parasitic load) will assist in achieving the minimu operating temperature is 8 0° C (176° F).

heaters (if equipped) heat the

is reduced.

topped. A block heater can be 110 V dc or

mation.

e Engine

increase the engine rpm from 1000 to 1200

will be easier with the installation of a hand

m operating temperature. The minimum

When starting a times without being operated in order to warm up completely, the carbon deposits become thicker. This starting problems:

Free operati

•

Valves become stuck.

•

Pushrods may become bent.

•

Other damag

•

result.

For this re the engine must be operated until the coolant temperature is 80° C (176° F) minimum. Carbon deposits o and the free operation of the valves and the valve components will be maintained.

The engine must be thoroughly warmed in order to keep other engine parts in better condition. The service l Lubrication will be improved. There will be less acid and less sludge in the oil. This condition will provide longer s rings, and other parts. However, limit unnecessary idle time to 10 minutes in order to reduce wear and unneces

ife of the engine will be generally extended.

ervice life for the engine bearings, the piston

sary fuel consumption.

nd stopping an engine many

and stopping can cause the following

on of the valves is prevented.

e to valve train components can

ason, when the engine is started,

n the valve stems will be kept at a minimum

The Water Temperature Regulator and Insula

ted Heater Lines

Recommendations for Coolant Warm U

Warm up an engine that has cooled below normal opera

-up should be performed before the engine is returned to full operation. During operation in very

temperature conditions, damage to engine

cold valve mechanisms can result from engine operation for short intervals. This damage can happen if the

ne is started and the engine is stopped many

engi times without being operated in order to warm up completely.

When the engine is operated below normal operating temperatures, fuel and oil are not completely burned

he combustion chamber. This fuel and oil causes

in t soft carbon deposits to form on the valve stems. Generally, the deposits do not cause problems and

e deposits are burned off during operation at

th normal engine operating temperatures.

ting temperatures due to inactivity. This warm

The engine is equipped with a water temperature

ator. When the engine coolant is below the

regul correct operating temperature, jacket water circulates through the engine cylinder block and into the

e cylinder head. The coolant then returns to the

engin cylinder block via an internal passage that bypasses the valve of the coolant temperature regulator. This

res that coolant ﬂows around the engine under

ensu cold operating conditions. The water temperature regulator begins to open when the engine jacket

r has reached the correct minimum operating

wate temperature. As the jacket water coolant temperature rises above the minimum operating temperature, the

er temperature regulator opens further allowing

wat more coolant through the radiator to dissipate excess heat.

The progressive opening of the water temperature regulator operates the progressive closing of the

pass passage between the cylinder block and

by head. This action ensures maximum coolant ﬂow to the radiator in order to achieve maximum heat

ssipation.

SEBU8605-01 61

Operation Section

Cold Weather Operation

Note: Do not res the air ﬂow can damage the fuel system. Perkins discourages the use of all air ﬂow restriction devices such a air ﬂow can result in the following: high exhaust temperatures, power loss, excessive fan usage, and reduction in

A cab heater is beneﬁcial in very cold weather. The feed from th cab should be insulated in order to reduce heat loss to the outside air.

trict the air ﬂow. Restriction of

s radiator shutters. Restriction of the

fuel economy.

eengineandthereturnlinesfromthe

Recommendation for Crankcase Breather Protection

Crankcase ventilation gases contain a large quantity of water vapor. This water vapor can freeze in cold ambie the crankcase ventilation system. If the engine is operated in temperatures below −25° C (−13° F), measures plugging of the breather system. Insulated hoses and a heated canister assembly should be installed.

Consult with your Perkins dealer or your Perkins distributer for the recommended breather compone (−13° to -72.°F).

nt conditions and can plug or damage

must be taken to prevent freezing and

nts for operation from −25° to -40°C

i02685960

Fuel and the Effect from Cold Weather

Note: Only use grades of fuel that are recommended

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

The following components provide a means of minimizing

Glow plugs (if equipped)

•

Engine coolant heaters, which may be an OEM

•

option

Fuel heaters, which may be an OEM option

•

Fuel line

•

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

The pour will thicken. The diesel fuel becomes more resistant to ﬂow through fuel lines, fuel ﬁlters,and fuel pumps.

uid Recommendations”.

problems in cold weather:

insulation, which may be an OEM option

s to form in the fuel. These crystals can cause

point is the temperature when diesel fuel

Be aware of these facts when diesel fuel is purchased. Consider the average ambient air temper are fueled in one climate may not operate well if the engines are moved to another climate. Problems can resul

Before troubleshooting for low power or for poor perfo

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

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

ature for the engine's application. Engines that

t due to changes in temperature.

rmance in the winter, check the fuel for waxing.

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

ther Operation and Fuel Related Components in

62 SEBU8605-01 Operation Section Cold Weather Operation

i02323237

Fuel Related Components in Cold Weather

Fuel Tanks

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

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

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

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

from the bottom of the tank. If the engine is

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

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

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

Fuel Fi

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

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

lters

nd the engine fuel inlet. After you change

Operation and Maintenance Manual in the

ly line are the most common components that

Fuel Heaters

e: The OEM may equip the application with fuel

Not

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

pum

For more information about fuel heaters (if equipped),

fer to the OEM information.

SEBU8605-01 63

Maintenance Section

Reﬁll Capacities

Maintenance Section

Reﬁll Capacities

i04262329

Reﬁll Capaci ties

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 6

Engine

Reﬁll Capacities

Compartment or System

Crankcase Oil Sump

(1)

The minimum value is the approximate capacity 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. The design of the oil pan can change the oil capacity of the oil pan.

(2)

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

Minimum

(1)

6L(1.32

Imp gal)

Maximum

(2)

14L(3.1

Imp gal)

Cooling System

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

64 SEBU8605-01 Maintenance Section Reﬁll Capacities

Table 7

Engine

Reﬁll Capacities

Compartment or System

Engine Engine

(1)

Engine Only

External System Per OEM

(1)

Single Turbocharger

(2)

Series Turbochargers

(3)

The External S ystem includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM speciﬁcations. Enter the value for the capacity of the External System in this row.

(3)

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

Liters

TTA

(2)

i04229329

Fluid Recommendations

General Coolant Information

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

NOTICE If the e with below freezing temperatures, the cooling system must be either protected to the lowest outside temperature

Frequently check the speciﬁc gravity of the coolant for proper freeze protection or for anti-boil protection.

Cle

•

Never operate an engine without water temperature r regulators help to maintain the engine coolant at the proper operating temperature. Cooling system probl tors.

ngine is to be stored in, or shipped to an area

or drained completely to prevent damage.

NOTICE

an the cooling system for the following reasons:

Contamination of the cooling system

Overheating of the engine

aming of the coolant

NOTICE

egulators in the cooling system. Water temperature

ems can develop without water temperature regula-

These failures can be avoided with correct cooling system ma

intenance. Cooling system maintenance is as important as maintenance of the fuel system and the lubrication system. Quality of the coolant is as importa

nt as the quality of the fuel and the lubricating

oil.

Coolant

is normally composed of three elements:

Water, additives, and glycol.

Water

Waterisusedinthecoolingsysteminorderto

er heat.

transf

Distilled water or deionized water is

mended for use in engine cooling systems.

recom

DO NOT use the following types of water in cooling

ms: Hard water, softened water that has been

syste conditioned with salt, and sea water.

stilled water or deionized water is not available,

If di use water with the properties that are listed in Table 8.

Table 8

Acceptable Water

Property Maximum Limit

Chloride (Cl) 40 mg/L

Sulfate (SO4)100mg/L

Total Hardness 170 mg/L

otal Solids

Acidity

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

40 mg/L

pH of 5.5 to 9.0

Many engine failures are related to the cooling system. The following problems are related to cooling system failures: Overheating, leakage of the water pump, and plugged radiators or heat exchangers.

Local water utility company

•

Agricultural agent

•

SEBU8605-01 65

Maintenance Section

Reﬁll Capacities

Independent la

•

boratory

Additives

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

Corrosion

•

Formation of mineral deposits

•

Rust

•

Scale

•

Foaming of the coolant

•

Many additives are depleted during engine operation. These additives must be replaced periodically.

Additives must be added at the correct concentration. Over concentration of additives can cause the inhibit enable the following problems to occur:

Formati

•

Reduction of heat transfer

•

Leakage of the water pump seal

•

Pluggi

•

amounts of additives enable the following

ors to drop out-of-solution. The deposits can

on of gel compounds

ng of radiators, coolers, and small passages

Table 9

Ethylene Glycol

Concentration Freeze Protection

50 Percent −36 °C (−33 °F)

60 Percent

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

Table 10

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.

−51 °C (−60 °

Coolant Recommendations

ELC____________________________ Extended Life Coolant

•

SCA___________________ Supplement Coolant Additive

•

ASTM__________________________________________ American

•

Society for Testing and Materials

Glycol

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

Boiling

•

zing

Free

•

Cavitation of the water pump

•

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

Note: Use a mixture that will provide protection against the lowest ambient temperature.

Note: 100 percent pure glycol will freeze at a temperature of −13 °C (8.6 °F).

Most conventional antifreezes use ethylene glycol. Propylene glycol may also be used. In a 1:1 mixture

th water, ethylene and propylene glycol provide

wi similar protection against freezing and boiling. Refer to Table 9 and refer to table 10.

The following two coolants are used in Perkins diesel engines:

Preferred – Perkins ELC

Acceptable – A commercial heavy-duty antifreeze

that meets “ASTM D6210 ” speciﬁcations

NOTICE

The 1200 series industrial engines must be operated with a 1:1 mixture of water and glycol. This concentration allows the NOx reduction system to operate correctly at high ambient temperatures.

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 an antifreeze. This ratio may be increased to 1:2 water to glycol if extra freezing protection is required.

66 SEBU8605-01 Maintenance Section Reﬁll Capacities

AmixtureofSCA

inhibitor and water is acceptable but will not give the same level of corrosion, boiling and, freezing protection as ELC. Perkins recommends a 6 percent to 8 pe

rcent concentration of SCA in those cooling systems. Distilled water or deionized water is preferred. Water which has the recommended properties m

Table 11

Commercia

Antifreeze that meets

“ASTM D6210”

Commercial SCA inhibitor

(1)

Use the interval that occurs ﬁrst. The cooling system must

also be ﬂushed out at this time.

ay be used.

Coolant Service Life

Coolant Type Service Life

Perkins ELC

lHeavy-Duty

and Water

6,000 Service Hours or

Three Years

3000 Service Hours or

Two Year

3000 Service Hours or

One Year

(1)

ELC

Perkins provides ELC for use in the following applications:

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 premixed cooling solution with distilled water. ELC is a 1:1 mixture. 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.

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

ELC Cooling System Maintenance

Correct ad ditions 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 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

Do not use standard supplemental coolant additive (SCA)

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

ELC Cooling System Cleaning

Note

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

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

the OEM in order to set the heater control. After

to the cooling system is drained and the cooling system is reﬁlled, operate the engine until the coolant level

eaches the normal operating temperature and

r until the coolant level stabilizes. As needed, add the coolant mixture in order to ﬁll the system to the

peciﬁed level.

recommendations can reduce cooling sys-

NOTICE

that is ﬁlled with Extended Life Coolant (ELC).

ﬁlters.

: If the cooling system is already using ELC,

nts are only required if the system has been

Changing to Perkins ELC

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

SEBU8605-01 67

Maintenance Section

Reﬁll Capacities

NOTICE Care must be ta 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 co

2. Dispose of the coolant according to local

regulatio

3. Flush the system with clean water in order to

remove any

4. Use an appropriate cleaner to clean the system.

Follow th

5. Drain the cleaner into a suitable container. Flush

the cool

6. Fill the cooling system with clean water and

operate 49° to 66°C (120° to 150°F).

Incorr can result in damage to copper and other metal components.

ing system with clean water.

the engine until the engine is warmed to

ect or incomplete ﬂushing of the cooling system

kentoensurethatallﬂuids are

epared to collect the ﬂuidwithsuitable

olant into a suitable container.

ns.

debris.

e instruction on the label.

NOTICE

ELC Cooling S ys

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 10 percent of conventional heavy-duty antifreeze or SCA. If the contamination exceeds 10 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 procedure 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.

tem Contamination

NOTICE

Commercial Heavy-Duty Antifreeze and SCA

To avoid damage to the cooling system, make sure to completely ﬂushthecoolingsystemwithclearwater.

inue to ﬂush the system until all the signs of the

Cont cleaning agent are gone.

7. Drai

Not

ﬂushed from the cooling system. Cooling system cleaner that is left in the system will contaminate the coo system.

8. Re

9. Fi

n the cooling system into a suitable container

and ﬂush the cooling system with clean water.

e: The cooling system cleaner must be thoroughly

lant. The cleaner may also corrode the cooling

peat Steps 6 and repeat steps 7 until the

system is completely clean.

ll the cooling system with the Perkins Premixed

ELC.

NOTICE

ercial Heavy-Duty Coolant which contains

Comm Amine as part of the corrosion protection system must not be used.

NOTICE 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. A hydrometer should not be used.

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

68 SEBU8605-01 Maintenance Section Reﬁll Capacities

Additions of SC

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

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

Use the equation that is in Table 12 to determine the amount of SCA that is required when the cooling system is in

Table 12

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.

itially ﬁlled.

Coolant At The Initial Fill

V × 0.045 = X

Table13isanexampleforusingtheequationthat is in Table 12.

Table 13

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant At The Initial Fill

Tot al Vo

of the Cooling

System (V)

15 L (4 US gal)

lume

Multipl

Factor

×0.045

ication

Amount of

SCA that is

Required (X)

0.7 L (24 oz)

Adding The SCA to The Heavy-Duty Coolant For Maintenance

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

Test the antifreeze periodically for the concentration of SCA. For the interval, refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section). Cooling System Supplemental Coolant Additive (SCA) Test/Add.

Table15isanex

ample for using the equation that

is in Table 14.

Table 15

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant For Maintenance

Total Volume

of the Cooling

System (V)

15 L (4 US gal)

Multiplication

Factor

×0.014

Amount of

SCA that is

Required (X)

0.2 L (7 oz)

Cleaning the System of H eavy-Duty Antifreeze

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.

i04156282

Fluid Recommendations

General Lubricant Information

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

API_____________________ American Petroleum Institute

•

SAE___________________________________________ Society Of

•

Automotive Engineers Inc.

ACEA__________________________________Association des

•

Constructers European Automobiles.

ECF-3_______________________ Engine Crankcase Fluid

•

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

Use the equation that is in Table 14 to determine the amount of SCA that is required, if necessary:

Table 14

Equation For Adding The SCA To The Heavy-Duty

is the total volume of the cooling system.

X is the amount of SCA that is required.

Coolant For Maintenance

V × 0.014 = X

Licensing

TheEngineOilLicensingandCertiﬁcation System by the American Petroleum Institute (API) and the Association des Constructers European Automobilesand (ACRA) is recognized by Perkins. For detailed information about this system, see the latest edition of the “API publication No. 1509”. Engine oils that bear the API symbol are authorized by API.

SEBU8605-01 69

Maintenance Section

Reﬁll Capacities

Illustration 42

Typical API symbol

g01987816

Termin olo gy

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

Engine Oil

The chemical li to maintain the expected life of the engine aftertreatment system. The performance of the engine aftert affected if oil that is not speciﬁed in table 16 is used.

Thelifeofyo the accumulation of ash on the surface of the ﬁlter. Ash is the inert part of the particulate matter. The system is de matter. There is a very small percentage of particulate matter that is left behind as the soot is burnt. This matter will of performance and increased fuel consumption. Most of the ash comes from the engine oil which is gradually ash is passes through the exhaust. To meet the designed life of the product, the use of the appropriate engine oil listed in table 16 has low ash content.

Maintena biodiesel – The oil change interval can be adversely

affected by the use of biodiesel. Use oil analysis in order to m 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

mits were developed in order

reatment system can be adversely

ur Aftertreatment system is deﬁned by

signed in order to collect this particulate

eventually block the ﬁlter, causing loss

consumed during normal operation. This

is essential. The oil speciﬁcation that is

nce intervals for engines that use

onitor the condition of the engine oil. Use

, CD, CD-2, CF-4, CG-4, CH-4, and CI-4.

Commercial Oils

NOTIC

Perkins require the use of the following speciﬁcation of engine oil. Failure to use the appropriate

ﬁcation of engine oil w ill reduce the life of

speci your engine. Failure to use the appropriate speciﬁcation of engine oil will also reduce the life of

aftertreatment system.

your

Table 16

Classiﬁcations for the 1200 Series Industrial Engine

Oil Speciﬁcation

API CJ-4 ACEA E9 ECF-3

API CJ-4 and ACEA E9 oil categories have the following chemical limits:

1 percent maximum sulfated ash

•

0.12 percent maximum phosphorous

•

Lubricant Viscosity Recommendations for Dir

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

Refer to illustration 43 (minimum temperature) in order to determine the required oil viscosity for star

Refer to illustration 43 (maximum temperature) in orde the highest ambient temperature that is anticipated.

Gen available to meet the requirement for the temperature at start-up.

ect Injection (DI) Diesel Engines

minimum ambient temperature during

ting a cold engine.

r to select the oil viscosity for engine operation at

erally, use the highest oil viscosity that is

0. 4 percent maximum sulfur

•

70 SEBU8605-01 Maintenance Section Reﬁll Capacities

Illustration 43

Lubricant Viscosities

Supplemental heat is recomme nded for cold soaked starts below the minimum ambient temperature. Supplemental heat may be required for cold soaked starts that are above the minimum temperature that is stated, de pending on the parasitic load and other factors. Cold soaked starts occur when the engine has not been operated for a period of time. This interval will allow the oil to become more v iscous due to cooler ambient temper atures.

g02210556

Aftermarket Oil Additives

Perkins does not recommend the use of aftermarket additives in oil. It is not necessary to use aftermarket additives in order to achieve the engines maximum service life or rated performance. Fully formulated, ﬁnished oils consist of base oils and of commercial additive packages. These additive packages are blended into the base oils at precise percentages in order to help provide ﬁnished oils with performance characteristics that meet industry standards.

Perform mainte

•

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

nance at the intervals that are

Oil analysis

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

The oil anal determine oil performance and component wear rates. Contamination can be identiﬁed and measured by using oi following tests:

The Wear Ra

•

engines metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increase oil is as important as the quantity of engine wear metal in the oil.

Tests are conducted in order to detect

•

contamination of the oil by water, glycol, or fuel.

The Oil Condition Analysis determines the loss of

•

the oils lubricating properties. An infrared analysis is used properties of the used oil sample. This analysis allows technicians to determine the amount of

oration of the oil during use. This analysis

deteri also allows technicians to verify the performance of the oil according to the speciﬁcation during the

e oil change interval.

entir

maybeequippedwithanoilsampling

ll complement the preventive maintenance

ysis is a diagnostic tool that is used to

l analysis. The oil analysis includes the

te Analysis monitors the wear of the

in the rate of engine wear metal in the

to compare the properties of new oil to the

i04224221

Fluid Recommendations

There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in ﬁnished oil. Aftermarket additives may not be compatible with the ﬁnished oils additive package, which could lower the performance of the ﬁnished oil. The aftermarket additive could fail to mix with the ﬁnished oil. This failure could produce sludge 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:

See the appropriate “Lubricant Viscosities”. Refer

•

totheillustration43inordertoﬁnd the correct oil viscosity grade for your engine.

At the speciﬁed interval, service the engine. Use

•

new oil and install a new oil ﬁlter.

Glossary

•

ISO International Standards Organization

•

ASTM American Society for T esting and Materials

•

HFRR High Frequency Reciprocating Rig for

•

Lubricity testing of diesel fuels

FAME Fatty Acid Methyl Esters

•

CFR Co-ordinating Fuel Research

•

ULSD Ultra Low Sulfur Diesel

•

RME Rape Methyl Ester

•

SEBU8605-01 71

Maintenance Section

Reﬁll Capacities

SME Soy Methyl E

•

EPA Environmental Protection Agency of the

•

ster

United States

PPM Parts Per Million

•

DPF Diesel Particulate Filter

•

General Information

NOTICE Every attempt is made to provide accurate, up-to-date information. By use of this document you agree that Perkins En

gines Company Limited is not responsible

for errors or omissions.

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

Diesel Fuel Requirements

Perkins is not in a position to continuously evaluate and monitor all worldwide distillate diesel fuel

cations that are published by governments and

speciﬁ technological societies.

The Per

kins Speciﬁcation for Distillate Diesel Fuel provides a known reliable baseline in order to judge the expected performance of distillate diesel fuels

re derived from conventional sources.

that a

Satisfactory engine performance is dependent on the

f a good quality fuel. The use of a good quality

use o fuel will give the following results: long engine life and acceptable exhaust emissions levels. The fuel

meet the minimum requirements that are stated

must in the table 17.

NOTICE

The footnotes are of the key part Perkins Speciﬁca-

n for Distillate Diesel Fuel Table. Read ALL of the

tio footnotes.

Table 17

Perkins Speciﬁcation for Distillate Diesel Fuel

Property

Aromatics

Ash

Carbon Residue on 10% Bottoms

Cetane Number

(2)

UNITS

%Volume 35% maximum

%Weight 0.01% maximum

%Weight 0.35% maximum

Requirements

40 minimum

(1)

“ASTM”Test “ISO”Test

D1319

D482

D524

D613/D6890 “ISO”5165

“ISO”3837

“ISO”6245

“ISO”4262

(continued)

72 SEBU8605-01 Maintenance Section Reﬁll Capacities

(Table 17, contd)

Cloud Point °C

The cloud point must not exceed the

lowest expected ambient temperature.

Copper Strip

No. 3 maximum D130 “ISO”2160

Corrosion

Density at 15 °C (59 °F)

(3)

Distillation

Kg / M

°C 10% at 282 °C

801 minimum and 876 maximum

(539.6 °F) maximum 90% at 360 °C (680 °F) maximum

Flash Point

Thermal Stability

°C

legal limit D93

Minimum of 80% reﬂectance after aging for 180 minutes at 150 °C (302 °F)

Pour Point °C 6 °C (42.8 °F) minimum

below ambient temperature

(1)

Sulfur

Kinematic Viscosity

%mass

(4)

“MM”2“/S (cSt)” The viscosity of the

0.0015

hat is delivered to

fuel t the fuel injection pump. “1.4 minimum/4.5

um”

maxim

Water and sediment

Water

% weight 0.1% maximum

Sediment % weight 0.05% maximum

Gums and Resins

(5)

mg/100mL

10 mg per 100 mL maximum

Lubricity corrected

0.52 maximum D6079

wear scar diameter at 60 °C (140 °F).

(1)

This s peciﬁc ation includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to

“ASTM D5453”, “ASTM D2622”, or “ISO 20846, ISO 20884” test methods.

(2)

A f uel with a higher cetane number is recommended in or der to operate at a higher altitude or in cold weather.

(3)

“Via standards tables, the equivalent AP I 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)

The values of the fuel v iscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscosity requirement and the fuel should m eet the maximum viscosity requirements at 40 °C (104 °F ) of either the “ASTM D445” test method or the “ ISO 3 104” test method. If a fuel with a low viscosity is used, cooling of the fuel m ay 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 “1.4 cSt” at the fuel injection pump.

(5)

Follow the test conditions and procedures for gasoline (m otor).

(6)

The lubricity of a fuel is a concern with ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or ASTM D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum require ments, consult your fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system.

(6)

is 30”.

D2500

No equivalent test

D86

“ISO”3015

“ISO 3675 ”“ISO 12185”

“ISO”3405

“ISO”2719

D6468 No equiva

lent test

D97 “ISO”3016

D5453/D26222 “ISO 20846 ”“ISO 20884”

D445

D1796

“ISO”3405

“ISO”3734

D1744 No equivalent test

D473

D381

“ISO”3735

“ISO”6246

SO”12156-1

“I

Engines that are manufactured by Perkins are certiﬁed with the fuel that is prescribed by the United States Environmental Protection Agency. Engines that are manufactured by Perkins are certiﬁed with the fuel that is prescribed by the European Certiﬁcation. Perkins does not certify diesel engines on any other fuel.

Note: The owner and the operator of the engine has the responsibility of using the fuel that is prescribed by the EPA and other appropriate regulatory agencies.

SEBU8605-01 73

Maintenance Section

Reﬁll Capacities

NOTICE

Operating wit

h fuels that do not meet the Perkins recommendations can cause the following effects: Starting difﬁculty, reduced fuel ﬁlter service life, poor combustion, depo

sits in the fuel injectors, signiﬁcantly reduce service life of the fuel system, deposits in the combustion chamber, and reduced service life of the engine.

NOTICE The Perkins 1200 series of diesel engine must be operated using Ultra Low Sulfur Diesel. The sulphur content of this fuel must be lower than 15 PPM. This fuel complies with the emissions regulations that are prescribed by the Environmental Protection Agency of the United States.

Illustration 44

g02157153

Illustration 44 is a representation of the label that will be installed next to the fuel ﬁller cap on the fuel tank of the application.

The fuel speciﬁcations that are listed in the table 18 are released as acceptable to use on all 1200 series of engine.

Table 18

Acceptable Fuel Speciﬁcation for the 1200 Series of Engines

Fuel Speciﬁcation Comments

EN590

“ASDM D975 GRADE 1D S15” “North American Light Distillate Diesel fuel with less than 15

“ASTM D975 GRADE 2D S15” “North American Middle Distillate general purpose Diesel fuel

“JIS K2204” “Japanese Diesel Fuel” Must meet the requirements that are

“BS 2869: 2010 CLASS A2 or EU equivalent ” “EU Off Road Diesel fuel. Acceptable from 2011 MUST have

(1)

All the fuels must comply with the speciﬁcation in the table for the Pe r k in s Speciﬁcation Distillate D iesel Fuel.

European Automotive Diesel Fuel (DERV)

PPM sulfur level”

with less than 15 PPM sulfur level”

stated in the section “Lubricity”.

less than 10 PPM sulfur level”

(1)

74 SEBU8605-01 Maintenance Section Reﬁll Capacities

Diesel Fuel Characteristics

Cetane Number

Fuel that has a high cetane number will give a shorter ignition delay. A high cetane number will produce a better ignition quality. Cetane numbers are derived for fuels against proportions of cetane and heptamethylnonane in the standard CFR engine. Refer to “ISO 5165” for the test method.

Cetane numbers in excess of 45 are normally expected from current diesel fuel. However, a cetane number of 40 may be experienced in some territories. The United States of America is one of the territories that can have a low cetane value. A minimum cetane value of 40 is required during average starting conditions. A fuel with higher cetane number is recommended for operations at high altitudes or in cold-weather operations.

Fuel with a low cetane number can be the root cause of problems during a cold start.

Viscosity

Viscosity is the property of a liquid of offering resistance to shear or ﬂow. Viscosity decreases with increasing temperature. This decrease in viscosity follows a logarithmic relationship for normal fossil fuel. The common reference is to kinematic viscosity. Kinematic viscosity is the quotient of the dynamic viscosity that is divided by the density. The determination of kinematic viscosity is normally by readings from gravity ﬂow 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 have sufﬁcient viscosity in order to lubricate the fuel system in both extremely cold temperatures and extremely hot temperatures. If the kinematic viscosity of the fuel is lower than “1.4 cSt” at the fuel injection pump, damage to the fuel injection pump can occur. This damage can be excessive scufﬁng and seizure. Low viscosity may lead to difﬁcult hot 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. If a fuel with a low viscosity 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.

Density

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

Perkins recommends a density of 841 kg/m to obtain the correct power output. Lighter fuels are acceptable power.

mperature. This parameter has a

tput given injected volume of fuel. This

but these fuels will not produce the rated

at 15 °C

in order

Sulfur

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

Perkins designed to operate only with ULSD. By using the test methods “ASTM D5453, ASTM D2622, or ISO 20846 IS must be below 15 PPM (mg/kg) or 0.0015% mass.

Use of d it in these engines will harm or permanently damage emissions control systems and/or shorten their service i

ons. Regional regulation, national regulations,

el quality must comply with all existing local

1200 series diesel engines have been

O 20884”, the content of sulfur in ULSD fuel

NOTICE

iesel fuel with higher than 15 PPM sulphur lim-

nterval.

Lubricity

icity is the capability of the fuel to prevent pump

Lubr wear. The ﬂuids lubricity describes the ability of the ﬂuid to reduce the friction between surfaces that are

r load. This ability reduces the damage that is

unde caused by friction. Fuel injection systems rely on the lubricating properties of the fuel. Until fuel sulfur limits

e mandated, the fuels lubricity was generally

wer believed to be a function of fuel viscosity.

lubricity has particular signiﬁcance to the current

The ultra low sulfur fuel, and low aromatic fossil fuels. These fuels are made in order to meet stringent

haust emissions.

The lubricity of these fuels must not exceed wear scar

ameter of 0.52 mm (0.0205 inch). The fuel lubricity

di test must be performed on an HFRR, operated at 60 °C (140 °F). Refer to “ISO 12156-1 ”.

SEBU8605-01 75

Maintenance Section

Reﬁll Capacities

NOTICE The fuels syst ing lubricity up to 0.52 mm (0.0205 inch) wear scar diameter as tested by “ISO 12156-1”. Fuel with higher wear scar diam lead to reduced service life and premature failure of the fuel system.

Fuel additives can enhance the lubricity of a fuel. Contact your fuel supplier for those circumstances when fuel ad can make recommendations for additives to use, and for the proper level of treatment.

em has been qualiﬁed with fuel hav-

eter than 0.52 mm (0.0205 inch) will

ditives are required. Your fuel supplier

Distillation

Distillat hydrocarbons in the fuel. A high ratio of light weight hydrocarbons can affect the characteristics of combusti

ion is an indication of the mixture of different

on.

Recommendation for B iodiesel

Biodiesel is a fuel that can be deﬁned as mono-alkyl esters of fatty acids. Biodiesel is a fuel that can be made fro available biodiesel in Europe is Rape Methyl Ester (REM). This biodiesel is derived from rapeseed oil. So biodiesel in the United States. This biodiesel is derived from soybean oil. Soybean oil or rapeseed oil are the known as Fatty Acid Methyl Esters (FAME).

Raw pr use as a fuel in any concentration in compression engines. Without esteriﬁcation, these oils solidify in the cr not be compatible with many of the elastomers that are used in engines that are manufactured today. In or as a fuel in compression engines. Alternate base stocks for biodiesel may include animal tallow, waste cook use any of the products that are listed as fuel, the oil must be esteriﬁed.

Fuel made of 100 percent FAME is generally referred to as B100 biodiesel or neat biodiesel.

Biodiesel can be blended with distillate diesel fuel. The blends can be used as fuel. The most commonly av biodiesel and 95 percent distillate diesel fuel. B20, which is 20 percent biodiesel and 80 percent distillate

esel fuel.

m various feedstock. The most commonly

y Methyl Ester (SME) is the most common

primary feedstocks. These fuels are together

essed vegetable oils are NOT acceptable for

ankcase and the fuel tank. These fuels may

iginal forms, these oils are not suitable for use

ing oils, or various other feedstocks. In order to

ailable biodiesel blends are B5, which is 5 percent

The U.S. distil D975-09a” includes up to B5 (5 percent) biodiesel.

European dist 2010 includes up B7 (7 percent) biodiesel.

Note: Engine are certiﬁed by use of the prescribed Environmental Protection Agency (EPA) and European Certiﬁcation fuels. Perk fuel. The user of the engine has the responsibility of using the correct fuel that is recommended by the manufac appropriate regulatory agencies.

Speciﬁcat

The neat biodiesel must conform to the latest “EN14214 o biodiesel can only be blended in mixture of up to 20% by volume in acceptable mineral diesel fuel meeting l designation.

In United meet the requirements listed in the latest edition of “ASTM D7467” (B6 to B20) and must be of an API gravity

In North America biodiesel and biodiesel blends must be p producers and BQ-9000 certiﬁed distributors.

In othe that is BQ-9000 accredited and certiﬁed, or that is accredited and certiﬁed by a comparable biodiesel quali standards is required.

Engin

Aggressive properties of biodiesel fuel may cause debr properties of biodiesel will clean the fuel tank and fuel lines. This cleaning of the fuel system can p recommend that after the initial usage of B20 biodiesel blended fuel the fuel ﬁlters must be replaced at 5

G fue the regular service interval should be reduced to 250 hours.

of 30-45.

r areas of the world, the use of biodiesel

ty body to meet similar biodiesel quality

e Service Requirements

is in the fuel tank and fuel lines. The aggressive

rematurely block of the fuel ﬁlters. Perkins

0 hours.

lycerides present in

l ﬁlters to become blocked more quickly. Therefore

late diesel fuel speciﬁcation “ASTM

illate diesel fuel speciﬁcation EN590:

s that are manufactured by Perkins

ins does not certify engines on any other

turer and allowed by the EPA and other

ion Requirements

rASTMD6751”(intheUSA).The

atest edition of “EN590 or ASTM D975 S15”

States Biodiesel blends of B6 to B20 must

urchased from the BQ-9000 accredited

biodiesel fuel will also cause

Note: The percentages given are volume-based.

76 SEBU8605-01 Maintenance Section Reﬁll Capacities

When biodiesel aftertreatment systems may be inﬂuenced. This inﬂuence is due to the chemical composition and characterist volatility, and to chemical contaminants that can be present in this fuel, such as alkali and alkaline metals (sodium, pot

Crankcase oil fuel dilution can be higher when

•

biodiesel o increased level of fuel dilution when using biodiesel or biodiesel blends is related to the typically lower volatility strategies utilized in many of the industrial latest engine designs may lead to a higher level of biodiesel effect of biodiesel concentration in crankcase oil is currently unknown.

Perkins recommend the use of oil analysis in order

•

to check the quality of the engine oil if biodiesel fuel is us the fuel is noted when the oil sample is taken.

Performa

Due to the lower energy content than the standard

ate fuel B20 will cause a power loss in order

distill of 2 to 4 percent. In addition, over time the power may deteriorate further due to deposits in the fuel

rs.

injecto

Biodiesel and biodiesel blends are known to cause

ease in fuel system deposits, most signiﬁcant

an incr of which are deposits within the fuel injector. These deposits can cause a loss in power due to restricted or mod issues associated with these deposits.

Note:

effective in cleaning and preventing the formation of deposits. Perkins Diesel Fuel Conditioner helps to li biodiesel and biodiesel blends. For more information refer to “Perkins Diesel Fuel System Cleaner”.

Biodiesel fuel contains metal contaminants (sodium, potassium, calcium, and/or magnesium) that form ash pro ash can have an impact on the life and performance of aftertreatment emissions control devices and can acc the need for more frequent ash service intervals and cause loss of performance

iﬁed fuel injection or cause other functional

Perkins T400012 Fuel Cleaner is most

mit deposit issues by improving the stability of

ducts upon combustion in the diesel engine. The

umulate in DPF. The ash accumulation may cause

fuel is used, crank case oil and

ics of biodiesel fuel, such as density and

assium, calcium, and magnesium).

r biodiesel blends are used. This

of biodiesel. In-cylinder emissions control

concentration in the sump. The long-term

ed. Ensure that the level of biodiesel in

nce Related Issues

General Requir

Biodiesel has poor oxidation stability, which can result in long-term p Biodiesel fuel should be used within 6 months of manufacture. Equipment should not be stored with the B20 biodi than 3 months.

Duetopooro issues, it is strongly recommended that engines with limited operational time either not use B20 biodiesel blends or, w blend to a maximum of B5. Examples of applications that should limit the use of biodiesel are the following: Standby Ge vehicles.

Perkins st operated engines have the fuel systems, including fuel tanks, ﬂashed with conventional diesel fuel before pr an application that should seasonally ﬂush the fuel system is a combine harvester.

Microbial contamination and growth can cause corrosion in the fuel system and premature plugging of the fu assistance in selecting appropriate anti-microbial additive.

Water accelerates microbial contamination and growth. When biodiesel is compared to distillate fuels, biodiesel. It is therefore essential to check frequently and if necessary, drain the water separator.

Materials such as brass, bronze, copper, lead, tin, and zinc accelerate the oxidation process of the biodi deposits formation therefore these materials must not be used for fuel tanks and fuel lines.

olonged shutdown periods. An example of

el ﬁlter. Consult your supplier of fuel for

water is naturally more likely to exist in the

esel fuel. The oxidation process can cause

ements

roblems in the storage of biodiesel.

esel blends in the fuel system for longer

xidation stability and other potential

hile accepting some risk, limit biodiesel

nerator sets and certain emergency

rongly recommended that seasonally

Fuel for Cold Weather Operation

uropean standard “EN590” contains climate

The E dependant requirements and a range of options. The options can be applied differently in each country.

re a re ﬁve classes that are given to arctic climates

The and severe winter climates. 0, 1, 2, 3, and 4.

l that complies with “EN590 ” CLASS 4 can be

Fue used at temperatures as low as −44 °C (−47.2 °F). Refer to “EN590” for a detailed discretion of the

ysical properties of the fuel.

The diesel fuel “ASTM D975 1-D” used in the

ited States of America may be used in very cold

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

SEBU8605-01 77

Maintenance Section

Reﬁll Capacities

Aftermarket Fu

Supplemental diesel fuel additives are not generally recommended. potential damage to the fuel system or the engine. Your fuel supplier or the fuel manufacturer will add the appropri

Perkins recognizes the fact that additives may be required in your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can recommend t correct level of treatment.

Note: For t treat the fuel when additives are required. The treated fuel must meet the requirements that are stated in table 17.

Perkins Diesel Fuel System Cleaner

Perkins T400012 Fuel Cleaner is the only fuel cleaner that is recommended by Perkins.

If biodiesel or biodiesel blends of fuel are to be used, Perkins require the use of Perkins fuel cleaner deposits within the fuel system that is created with the use of biodiesel. For more information on the use o “Recommendation for Biodiesel”.

ate supplemental diesel fuel additives.

some special circumstances. Contact

he best results, your fuel supplier should

. The use of the fuel is in order to remove

f biodiesel and biodiesel blends refer to

el Additives

This recommendation is due to

he appropriate fuel additive and the

s fuel cleaner will remove deposits that can

Perkin form in the fuel system with the use of biodiesel and biodiesel blends. These deposits can create a loss

er and engine performance.

of pow

Once the fuel cleaner has been added to the fuel,

posits within the fuel system are removed

the de after 30 hours of engine operation. For maximum results, continue to use the fuel cleaner for up to

urs. Perkins fuel cleaner can be used on an

80 ho on-going basis with no adverse impact on engine or fuel system durability.

Details instruction on the rate of which the fuel cleaner must be use are on the container.

Note: Perkins fuel cleaner is compatible with existing and U.S. EPA Tier 4 nonroad certiﬁed diesel engine

ssion control catalysts and particulate ﬁlters.

emi Perkins fuel system cleaner contains less than 15 ppm of sulfur and is acceptable for use with ULSD

el.

78 SEBU8605-01 Maintenance Section Maintenance Recommendations

Maintenance Recommendations

i03648938

System Pressure Release

Coolant S ystem

Pressurized system: Hot coolant can cause serious burn. T diator is cool. Then loosen cap slowly to relieve the pressure.

The engine can have the ability to auto start. Ensure that the power supply is isolated before any service or repai

To relieve the pressure from the coolant system, turn off the e to cool. Remove the cooling system pressure cap slowly in order to relieve pressure.

o ope n cap, stop engine, wait until ra-

risperformed.

ngine. Allow the cooling system pressure cap

Before any serv engine fuel lines, perform the following tasks:

1. Stop the engin

2. Wait for 10 minutes.

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

ice or repair is performed on the

Engine Oil

To relieve pressure from the lubricating system, turn off the engine.

i04103081

Welding on Engines with Electronic Controls

NOTICE Because the strength of the frame may decrease, some manufacturers do not recommend welding onto a chassis frame or rail. Consult the OEM of the equipment or your Perkins dealer regarding welding on a chassis frame or rail.

Fuel System

To relieve the pressure from the fuel system, turn off the engine.

High Pressure Fuel Lines

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

This is because of the following differences:

The high pressure fuel lines are constantly charged

•

with high pressure.

Proper welding procedures are necessary in order to avoid damage to the engines 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 on a unit equipped with an Electronic Engine. The following procedure is considered to be the safest procedure to weld on a component. This procedure should provide a minimum risk of damage to electronic components.

ICE

NOT Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can

use damage to the drive train bearings, hydraulic

ca 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

s possible to the weld. This will help reduce the pos-

a sibility of damage.

ote: Perform the welding in areas that are free from

explosive hazards.

The internal pressures of the high pressure fuel

•

lines are higher than other types of fuel system.

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

OFF position.

SEBU8605-01 79

Maintenance Section

Maintenance Recommendations

2. Ensure that the

fuel supply to the engine is turned

off.

3. Disconnect th

e negative battery cable from the battery. If a battery disconnect switch is provided, open the switch.

4. Disconnect all electronic components from the wiring harnesses. Include the following components

Electronic components for the driven equipment

•

ECM

•

Sensors

•

Electronically controlled valves

•

Relays

•

Aftertre

•

atment ID module

NOTICE Do not use electrical components (ECM or ECM sensors) or electronic component grounding points for groundi

ng the welder.

Illustration 45

Use the e the grou compon

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

(9) The component that is being welded (10) Current path of the welder (11) Ground clamp for the welder

xample above. The current ﬂow from the welder to

nd clamp of the welder will not dam age any associated

ents.

and any electrical/electronic com ponent

g01075639

5. Connect the welding ground cable directly to the part that will be welded. Place the ground

eascloseaspossibletotheweldinorderto

cabl reduce the possibility of welding current damage to the following components. Bearings, hydraulic

ponents, electrical components, and ground

com straps.

e: If electrical/electronic components are used

Not

as a ground for the welder, or electrical/electronic components are located between the welder ground

d the weld, current ﬂow from the welder could

an severely damage the component.

otect the wiring harness from welding debris

6. Pr and spatter.

se standard welding practices to weld the

7.U

materials.

80 SEBU8605-01 Maintenance Section Maintenance Interval Schedule

i04238330

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 81

Battery or Battery Cable - Disconnect .................. 82

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

Clean/Replace .................................................... 90

Engine Air C

Inspect/Replace .................................................. 92

Engine Oil Sample - Obtain .................................. 96

Fuel Syste

Severe Service Application - Check ................... 108

Daily

Cooling System Coolant Level - Check ................ 87

Driven Equipment - Check .................................... 89

Engine Ai

Engine Air Precleaner - Check/Clean ................... 93

Engine O il Level - Check ...................................... 96

Fuel Sys

Drain ................................................................. 103

Walk-Around Inspection ....................................... 110

an ...................................................... 89

leaner Element (Single Element) -

m - Prime ........................................... 100

r Cleaner Service Indicator - Inspect ..... 92

tem Primary Filter/Water Separator -

Every 1500 Serv

Engine Crankcase Breather Element - Replace ... 93

Every 2000 Ser

Aftercooler Core - Inspect ..................................... 81

Alternator -

Engine Mounts - Inspect ....................................... 95

Starting Motor - Inspect ...................................... 108

Turbocharg

Inspect ............................................... 81

er - Inspect ........................................ 109

ice Hours

vice Hours

Every 3000 Service Hours

Alternator

Belt Tensioner - Inspect ........................................ 83

Radiator Pressure Cap - Clean/Replace ............ 107

Every 3000

Cooling System Coolant (Commercial Heavy-Duty) -

Change ............................................................... 84

and Fan Belts - Replace ....................... 81

ServiceHoursor2Years

Every 4000 Service Hours

Aftercoo

ler Core - Clean/Test ............................... 81

Every 12 000 Service Hours or 6 Years

Cooling

System Coolant (ELC) - Change ............. 85

Every We

Hoses and Clamps - Inspect/Replace ................ 105

Every 5

Fuel Tank Water and Sediment - Drain ............... 105

Every

Belt - Inspect ......................................................... 83

Engin

Fan Clearance - Check ......................................... 99

0 Service Hours or Weekly

500 Service Hours

e Oil and Filter - Change ............................. 97

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 82

Cooling System Supplemental Coolant Additive

) - Test/Add ................................................. 88

(SCA Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 90

ine Air Cleaner Element (Single Element) -

Eng

Inspect/Replace .................................................. 92

Fuel System Primary Filter (Water Separator)

ment - Replace ............................................ 101

Ele

Fuel System Secondary Filter - Replace ............ 103

Radiator - Clean .................................................. 107

Commissioning

Fan Cle

arance - Check ......................................... 99

ery 1000 Service Hours

Water Pump - Inspect .......................................... 112

SEBU8605-01 81

Maintenance Section

Aftercooler Core - Clean/Test

i01807350

Aftercooler Cor e - Clean/Test (Air-To-Air A

Theair-to-airaftercoolerisOEMinstalledinmany applications. Please refer to the OEM speciﬁcations for informa

tion that is related to the aftercooler.

Aftercoole

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

Inspect the aftercooler for these items: damaged ﬁns, corrosion, dirt, grease, insects, leaves, oil, and other debris. C

For air-to-air aftercoolers, use the same methods that are used

lean the aftercooler, if necessary.

for cleaning radiators.

ftercooler)

i02322295

r Core - Inspect

i02322311

Alternator - Inspect

Perkins recom the alternator. Inspect the alternator for loose connections and correct battery charging. Check the ammeter (if e order to ensure correct battery performance and/or correct performance of the electrical system. Make repairs, as

Check the alternator and the battery charger for correct op charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries affects the cranking power. If the battery is too cold, the battery will not crank the engine. When the engine is engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easi

mends a scheduled inspection of

quipped) during engine operation in

required.

eration. If the batteries are correctly

should be kept warm because temperature

not run for long periods of time or if the

ly than a battery with a full charge.

i02680137

Personal injury can result from air pressure.

Person 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.

After cleaning, start the engine and accelerate the engine to high idle rpm. This will help in the removal of de Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if nece

Inspect the ﬁns for damage. Bent ﬁns may be opened wit

Note: If parts of the aftercooler system are repaired or r

Inspect these items for good condition: Welds, mo and seals. Make repairs, if necessary.

al injury can result without following prop-

bris and drying of the core. Stop the engine.

ssary.

ha“comb”.

eplaced, a leak test is highly recommended.

unting brackets, air lines, connections, clamps,

Alternator and Fan Belts Replace

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

i03559623

Battery - Replace

Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can re sult in severe personal injury or death.

Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced.

82 SEBU8605-01 Maintenance Section Battery Electrolyte Level - Check

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

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

1. Switch the engine to the OFF position. Remove

all electrical loads.

2. Turn off any battery chargers. Disconnect any

battery chargers.

3. Ensure that the battery disconnect switch is in the

OFF position.

4. Disconnect the NEGATIVE “-” cable from the

NEGATIVE “-” battery terminal.

5. Disconnect the POSITIVE “+” cable from the

POSITIVE “+” battery terminal.

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

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

1. Remove the ﬁller caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

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

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

3. Install the caps.

4. Keep the batteries clean.

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

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

•

and 1 L (1 qt) of clean water.

Use a solution of ammonium hydroxide.

•

6. Remove the used battery.

7. Install the new battery.

Note: Before the cables are connected, ensure that

the battery disconnect switch is in the OFF position.

8. Connect the POSITIVE “+” cable to the POSITIVE “+” battery terminal.

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

10. Turn the battery disconnect switch to the ON position.

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.

Thoroughly rinse the battery case with clean water.

i02323088

Batte

ry or Battery Cable -

Disconnect

battery cables or the batteries should not be

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

is attempted.

ing

Removing the battery cables or the batteries with

e cover in place may cause a battery explosion

th resulting i n personal injury.

rn the start switch to the OFF position. Turn the

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

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

our 12 volt batteries are involved, two negative

f connection must be disconnected.

SEBU8605-01 83

Maintenance Section

Belt - Inspect

3. Remove the posi

4. Clean all disconnected connection and battery

terminals.

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

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

7. Proceed with necessary system repairs.

8. In order to

positive connection before the negative connector.

tive connection.

dthecableclamps.Cleantheitems

cancausetheclampstonotﬁt

connect the battery, connect the

i03973719

Belt-Inspect

Inspect the bel

•

displacement of the cord and evidence of ﬂuid contamination.

The belt must be replaced if the following conditions are present.

The belt has a crack in more than one rib.

•

More than on

•

one rib of a maximum length of 50.8 mm (2 inch).

To replace t Assembly, “Alternator Belt - Remove and Install”. If necessary, replace the belt tensioner. Refer to Disasse Remove and Install” for the correct procedure.

Belt Tens

t for cracks, splits, glazing, grease,

e section of the belt is displaced in

he belt, refer to Disassembly and

mbly and Assembly, “Alternator Belt -

i03868550

ioner - Insp ect

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

Illustration 46

Typical example

To maximize the engine performance, inspect the belt (1) for wear and for cracking. Replace the belt if the belt is worn or damaged.

g01906354

Illustration 47

Typical exa mple

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 (2) for damage. Check that the pulley on the tensioner rotates freely and that the bearing is not loose. Some engines have an idler pulley (1). Ensure that the idler pulley is securely installed. Visually inspect the idler pulley for damage. Ensure that the idler pulley can rotate freely and that the bearing is not loose. If necessary, replace damaged components.

g02111454

84 SEBU8605-01 Maintenance Section Cooling System Coolant (Commercial Heavy-Duty) - Change

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

t. Refer to Disassembly and Assembly,

i04262370

Cooling System Coo lant (Commercial Heavy-Du ty) Change

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

Dispose of all ﬂuids according to Local regulations and mandates.

NOTICE Keep all parts clean from contaminants.

Drain

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

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

Loosen the cooling system ﬁller cap slowly in order to rel system ﬁller cap.

ystem: Hot coolant can cause seri-

re cool. Loosen the cooling system

ieve any pressure. Remove the cooling

Contaminants may cause rapid wear and shortened component life.

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

The engine overheats frequently.

•

Foaming of the coolant is observed.

•

The oil has entered the cooling system and the

•

coolant is contaminated.

The fuel has entered the cooling system and the

•

coolant is contaminated.

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

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

Illustration 48

Typical exa mple

2. Open the drain cock or remove the drain plug (1) on the engine. Also, remove the drain plug (2). Open the drain cock or remove the drain plug on the radiator.

Note: Some applications have two drain plugs on the cooler, only one is required for draining.

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.

g02119093

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

SEBU8605-01 85

Maintenance Section

Cooling System Coolant (ELC) - Change

Flush

1. Flush the cool

to remove any debris.

2. Close the drai Close the drain cock or install the drain plug on the radiator.

Do not ﬁll th (1.3 US gal) per minute, in order to avoid air locks.

Cooling sy

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

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

5. Stop the engine and allow the engine to cool. Loosen t order to relieve any pressure. Remove the cooling system ﬁller cap. Open the drain cock or remove the drai or remove the drain plug on the radiator. Allow the water to drain. Flush the cooling system with clean w

ing system with clean water in order

n cock or install the drain plugs.

NOTICE

e cooling system faster than 5 L

stem air locks may result in engine damage.

stem ﬁller cap.

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

he cooling system ﬁller cap slowly in

n plug on the engine. Open the drain cock

ater.

Fill

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

e. Close the drain cock or install the drain

engin plug on the radiator.

4. Maintain the co that is correct for your application.

Illustration 49

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 test the pressure of the ﬁller cap. The correct pressure is stamped on the face of the ﬁller cap. If the ﬁller cap does not retain the correct pressure, install a new ﬁller cap.

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

olant level at the maximum mark

g00103639

i04262389

Cooling System Coola nt ( ELC)

-Change

NOTICE Do no (1.3 US gal) per minute, in order to avoid air locks.

Cool

2. Fill the cooling system with Commercial

3. Start and run the engine at low idle. Increase

t ﬁll the cooling system faster than 5 L

ing system air locks may result in engine damage.

vy-Duty Coolant. Add Supplemental Coolant

Hea Additive to the coolant. For the correct amount, refer to the Operation and Maintenance Manual,

luid Recommendations” topic (Maintenance

“F Section) for more information on cooling system speciﬁcations. Do not install the cooling system

ler cap.

ﬁl

he engine rpm to high idle. Operate the engine

t in order to open the engine thermostat. This procedure will allow any air in the system to be

urged. Decrease the engine speed to low idle.

p Stop the engine.

Dispose of all ﬂuids according to Local regulations and mandates.

OTICE

N Keep all parts clean from contaminants.

ontaminants may cause rapid wear and shortened

C component life.

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

86 SEBU8605-01 Maintenance Section Cooling System Coolant (ELC) - Change

The engine over

•

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 temperatu been drained. This inspection is a good opportunity to replace the water pump, the water temperature regulator

When any servicing or repair of the engine cooling syste performed with the engine on level ground. This procedure will allow you to accurately check the coolant level. T of introducing an air lock into the coolant system.

re regulator after the cooling system has

, and the hoses, if necessary.

m is performed, the procedure must be

hisprocedurewillalsohelpinavoidingtherisk

heats frequently.

NOTICE

Illustration 50

Typical exa mple

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

on the engine. Also remove the drain plug (2). Open the drain cock or remove the drain plug on the radiator.

g02119093

Drain

urized System: Hot coolant can cause seri-

Press ous burns. To open the c ooling system ﬁller cap, stop the engine and wait until the cooling system compo pressure cap slowly in order to relieve the pressure.

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

nents are cool. Loosen the cooling system

Loosen the cooling system ﬁller cap slowly in

r to relieve any pressure. Remove the cooling

orde system ﬁller cap.

Note: Some applications have two drain plugs on the cooler, only one is required for draining.

Allow the coolant to drain.

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

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

2. Close the drain cock or install the drain plugs.

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, in order to avoid air locks.

Cooling system air locks may result in engine damage.

SEBU8605-01 87

Maintenance Section

Cooling System Coolant Level - Check

3. Fill the coolin cooling system ﬁller cap.

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

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

g system with clean water. Install the

he engine at low idle until the

ne and allow the engine to cool.

r cap. Open the drain cock or remove

drain. Flush the cooling system with

Fill

1. Close the d

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

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

Cooling system air locks may result in engine damage.

rain cock or install the drain plug on the

NOTICE

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 test the pressure of the ﬁller cap. The correct pressure is stamped on the face of the ﬁller cap. If pressure, install a new ﬁller cap.

6. Start the en leaks and for correct operating temperature.

ng system ﬁller cap and inspect the

, use a suitable pressurizing pump

the ﬁller cap does not retain the correct

gine. Inspect the cooling system for

i03576064

Cooling System Coolant Level

- Check

Engines With a Coolant Recovery Tank

Note: The cooling system may not have been

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

2. Fill th

3. Start and run the engine at low idle. Increase the

4. Maintain the coolant level at the maximum mark

e cooling system with Extended Life Coolant (ELC). Refer to the Operation and Maintenance Manual, “Fluid Recommendations”

Maintenance Section) for more information

topic ( on cooling system speciﬁcations. Do not install the cooling system ﬁller cap.

engine rpm to high idle. Operate the engine in

to open the engine thermostat. Operate

order the engine will allow any air in the system to be purged. Decrease the engine speed to low idle.

the engine.

Stop

is correct for your application.

that

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

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

1. Observe the coolant level in the coolant recovery

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

2. Loosen ﬁller cap slowly in order to relieve any

pressure. Remove the ﬁ ller cap.

Illustration 51

Filler cap

g00103639

88 SEBU8605-01 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add

3. Pour the correc Refer to the Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations” for information o coolant. Refer to the Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations” for the cooli coolant recovery tank above “COLD FULL” mark.

Illustration 52

4. Clean ﬁller cap and the receptacle. Reinstall the ﬁller cap and inspect the cooling system for leaks.

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

t coolant mixture into the tank.

n the correct mixture and type of

ng system capacity. Do not ﬁll the

g00103639

Engines Without a Coolant Recovery Tank

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

1. Remove the cooling system ﬁller cap slowly in

order to relieve pressure.

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

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

4. Inspect the cooling system for leaks.

948

i03644

Cooling System Supplemental Coolan

t Additive (SCA) -

Test/Add

Illustration 53

Cooling system ﬁller cap

0285520

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

Test for SCA Concentration

Heavy-Duty Coolant/Antifreeze and SCA

NOTICE

not exceed the recommended six percent supple-

Do mental coolant additive concentration.

Use a Coolant Conditioner Test Kit in order to check

he concentration of the SCA.

SEBU8605-01 89

Maintenance Section

Driven Equipment - Check

Add the SCA, If Necessary

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

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

e engine and wait until the cooling system

4. Clean the cooli

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

Driven Equ

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

•

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

nequipment:

Inspection

Adjustment

Lubrica

Other maintenance recommendations

tion

ng system ﬁller cap and inspect the

, use a suitable pressurizing pump

does not retain the correct pressure,

i02151646

ipment - Check

1. Slowly loosen the cooling system ﬁller cap in

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

Note: Always discard drained ﬂuids according to local regulations.

2. If necessary, drain some coolant from the cooling

system into a suitable container in order to allow spacefortheextraSCA.

3. Add the correct amount of SCA. Refer to the

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

i03991933

Engine - Clean

Personal i njury or death can result from high voltage.

Moisture can create paths of electrical conductivity.

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

NOTICE

cumulatedgreaseandoilonanengineisaﬁre haz-

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

he engine.

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

90 SEBU8605-01 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace

Easy detection

•

Maximum heat transfer characteristics

•

Ease of maintenance

•

Note: Cautio electrical components from being damaged by excessive water when the engine is cleaned. Pressure wa directed at any electrical connectors or the junction of cables into the rear of the connectors. Avoid electrical components the ECM. Protect the fuel injection pump from ﬂuids in order to wash the engine.

of ﬂuid leaks

nmustbeusedinordertoprevent

shers and steam cleaners should not be

such as the alternator, the starter, and

Aftertreatment

During the engine cleaning process, ensure that water or cleaning ﬂuids cannot enter the aftertre aftertreatment system, damage could occur.

atment system. If cleaning ﬂuids enters the

i02334355

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

Check the precl

•

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

Operating in dirty conditions may require more

•

frequent service of the air cleaner element.

The air cleaner element should be replaced at least

•

one time per year. This replacement should be performed r

Replace the dirty air cleaner elements with clean air cleaner ele elements should be thoroughly checked for tears and/or holes in the ﬁlter material. Inspect the gasket or the seal Maintain a supply of suitable air cleaner elements for replacement purposes.

ments. Before installation, the air cleaner

of the air cleaner element for damage.

eaner (if equipped) and the dust

egardless of the number of cleanings.

Dual Element Air Cleaners

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

The prim to six times if the element is properly cleaned and properly inspected. The primary air cleaner element should b replacement should be performed regardless of the number of cleanings.

lement air cleaner contains a primary air

ary air cleaner element can be used up

e replaced at least one time per year. This

NOTICE Never run the engine without an air cleaner element

lled. Never run the engine with a damaged air

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

e causes premature wear and damage to engine

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

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

Servicing the Air Cleaner Elements

Note: The air ﬁlter system may not have been

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

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

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

ace the secondary air cleaner element.

to repl

When the engine is operating in environments that

sty or dirty, air cleaner elements may require

are du more frequent replacement.

0736431

Illustration 54

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

emove the cover. Remove the primary air

1.R

cleaner element.

SEBU8605-01 91

Maintenance Section

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

2. The secondary a

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 cleane

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.

r element that is new or cleaned.

ir cleaner element should be

Cleaning the Primary Air Cleaner Elements

Refer to the OEM information in order to determine the numb be cleaned. When the primary air cleaner element is cleaned, check for rips or tears in the ﬁlter material. The prim at least one time per year. This replacement should be performed regardless of the number of cleanings.

er of times that the primary ﬁlter element can

ary air cleaner element should be replaced

Visually inspe before cleaning. Inspect air cleaner elements for damage to the pleats, the seals, the gaskets and the outer cove element.

Two methods m primary air cleaner element:

pressurize

•

Vacuum cleaning

•

ct the primary air cleaner element

r. Discard any damaged air cleaner

ay be used in order to clean the

dair

Pressurized Air

Personal injury can result from air pressure.

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

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

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

NOTICE Do not tap or strike the air cleaner element.

Do not

Use low pressure (207 kPa; 30 psi maximum) pressuris air cleaner element.

Tak e cleaner elements.

Do no pleats, gaskets or seals.

Ref the number of times that the primary air cleaner element can be cleaned. Do not clean the primary ai 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.

wash the primary air cleaner element.

ed air or vacuum cleaning to clean the primary

extreme care in order to avoid damage to the air

t use air cleaner elements that have damaged

er to the OEM information in order to determine

r ﬁlter element more than three times. The primary

Illustration 55

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

92 SEBU8605-01 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace

Vacuum Cleanin

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

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

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

ch require daily cleaning because of a

om the clean side (inside) with pressurized

irt from the dirty side (outside) of a

Inspecting the Primary Air Cleaner Elements

i02152042

Engine A ir Cleaner Element (Sing

le Element) -

Inspect/Replace

Refer to Operation and Maintenance Manual, “Engine Air Cleaner

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

Service Indicator-Inspect”.

NOTICE

since this will allow dirt to enter the engine.

693

Illustration 56

Inspect the clean, dry primary air cleaner element. Usea60wattbluelightinadarkroomorinasimilar

ity. Place the blue light in the primary air cleaner

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

or holes. Inspect the primary air cleaner element

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

rimary air cleaner element to a new primary air

the p cleaner element that has the same part number.

ot use a primary air cleaner element that has

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

ats, gaskets or seals. Discard damaged primary

ple air cleaner elements.

g00281

A wide variety of air cleaners may be installed for use

is engine. Consult the OEM information for the

with th correct procedure to replace the air cleaner.

i02335405

Engin

e Air Clean er Service

Indicator - Inspect

Some engines may be equipped with a different

vice indicator.

ser

Some engines are equipped with a differential gauge

inlet air pressure. The differential gauge for inlet

for air pressure displays the difference in the pressure that is measured before the air cleaner element and

e pressure that is measured after the air cleaner

th element. As the air cleaner element becomes dirty, the pressure differential rises. If your engine is

uipped with a different type of service indicator,

eq follow the OEM recommendations in order to service the air cleaner service indicator.

The service indicator may be mounted on the air cleaner element or in a remote location.

SEBU8605-01 93

Maintenance Section

Engine Air Precleaner - Check/Clean

i02343354

Engine Air Precleaner Check/Clean

Illustration 57

Typical service indicator

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

The yellow diaphragm enters the red zone.

•

The red piston locks in the visible position.

•

g00103777

Test the Service Indicator

Service indicators are important instruments.

Check for ease of resetting. The service indicator

•

should reset in less than three pushes.

Check the movement of the yellow core when

•

the engine is accelerated to the engine rated speed. The yellow core should latch at the greatest vacuum that is attained.

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.

tion 58

Illustra

Typical exa mple

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

Remove w accumulation of dirt and debris in body (3). Clean the body, if necessary.

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

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

ing nut (1) and cover (2). Check for an

g00287039

i04243333

Engine Crankcase Breather Element - Replace

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

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

ntact the skin.

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

94 SEBU8605-01 Maintenance Section Engine Crankcase Breather Element - Replace

NOTICE

Care must be ta

ken to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the ﬂu

id with suitable containers before opening any compartment or disassembling any component containing ﬂuids.

Dispose of all ﬂuids according to Local regulations and mandates.

The c rankca

se breather is a very important component in order to keep your engine emissions compliant.

The ﬁlter element within the crankcase breather

•

must be serviced at the prescribed service interval.

The correct ﬁlter element must be installed before

•

the engine is operated.

Theinstallationoftheﬁlter element is very

•

important.

The quality of the ﬁlter element that is installed is

•

very important.

The ﬁlter element protects the engine from

•

excessive quantities of oil from entering the

ion system. The ﬁlter element also protects

induct the engine aftertreatment system.

Note: E

xcessive quantities of oil that enter the induction system of the engine can rapidly increase the engine speed without control.

For information on aftermarket products, refer to Operation and Maintenance Manual, “Engine

ription”. Within that section, refer to the title

Desc “Aftermarket Products and Perkins Engines”.

Illustration 59

Typical exa mple

g02415998

1. Ensure that dirt cannot enter the breather assembly. Ensure that the outside body of the breather assembly is clean and free from damage. Place a container under the breather assembly.

2. Rotate the cap (1) counterclockwise into the unlocked position. Remove the cap from the body of the breather (3).

3. Note the orientation of the ﬁlter element (2). Remove the ﬁlter element .

Illustration 60

(B) Alignment position

g01884135

4. Remove the old seal (4) and install a new seal.

SEBU8605-01 95

Maintenance Section

Engine Mounts - Inspect

Note: The cut aw

ay from section (5) in the cap allows

access to the seal.

5. Install a new ﬁ

lter element into the breather body (3) and orient the ﬁlter element so that position (A) is aligned. Refer to illustration 59. Align position (B) on the cap

with position (A) on the ﬁlter

element.

Illustration 61

Typical example

g02415999

6. Install the cap (1). Rotate the cap by hand clockwise until the cap locks into the locked position C on the breather body.

7. Remove the container.

Check the System

Illustration 62

Typical exa mple

(1) Conn ection to breather cap for the engine (2) Oil drain (3) Tube assembly to atmosphere (4) Outlet

g02416001

Check the system for damage. Replace any component that is damaged. Ensure that the outlet (4) is clear and free from obstructions.

323089

i02

Engine Moun ts - Inspect

e: The engine mounts may not have been

Not

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

rrect bolt torque.

Inspect the engine mounts for deterioration and for

rrect bolt torque. Engine vibration can be caused

co by the following conditions:

ncorrect mounting of the engine

•

Deterioration of the engine mounts

•

Loose engine mounts

•

96 SEBU8605-01 Maintenance Section Engine Oil Level - Check

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

t that shows deterioration should

i03996001

Engine Oil Level - Check

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

hot c omponents can cause personal

If an increase i Troubleshooting, “Oil Contains Fuel”.

n the oil level is noticed, refer to

i01907674

Engine Oil Sample - Obtain

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

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

3847

Illustration 63

“L” Low

“H” Hi

NOTICE

Perform this maintenance with the engine stopped.

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

Note: After the engine has been switched OFF, wait for 10 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 mark (L) and the mark (H) on the engine oil dipstick. Do not ﬁll the crankcase above the “H”.

NOTICE Operating your engine when the oil level is above the “FULL” mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into the oil reduces the oil's lubricating characteristics and could result in the loss of power.

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

Clean the oil ﬁller cap. Install the oil ﬁller cap.

g0217

Obtain the Sample and the Analysis

Hot o il 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

•

Engine model

•

Engine number

•

Service hours on the engine

•

The number of hours that have accumulated since

•

the last oil change

The amount of oil that has been added since the

•

last oil change

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

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

SEBU8605-01 97

Maintenance Section

Engine Oil and Filter - Change

To avoid contam 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 exis the oil, and the existence of any nonferrous metal particles in the oil.

ination of the oil samples, the tools

tence of any ferrous metal particles in

i03886201

Engine Oil and Filter - C ha nge

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

NOTICE Care mus during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collec 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.

t be taken to ensure that ﬂuids are contained

ttheﬂuid with suitable containers before open-

NOTICE

After the engin temperature, stop the engine. Use one of the following methods to drain the engine oil pan:

Illustration 64

If the engine is equipped with a drain valve (2),

•

turn the drain valve knob counterclockwise in order to drain the oil. After the oil has drained, turn the drain valve knob clockwise in order to close the drain valve.

If the engine is not equipped with a drain valve,

•

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

e has been run at the normal operating

g02131361

Contaminants may cause rapid wear and shortened component life.

ot drain the engine lubricating oil when the

Do n engine is cold. As the engine lubricating oil cools, suspended waste particles settle on the bottom of

oil pan. The waste particles are not removed with

the draining cold oil. Drain the oil pan with the engine stopped. Drain the oil pan with the oil warm. This

aining method allows the waste particles that are

dr suspended in the oil to be drained properly.

ilure to follow this recommended procedure will

Fa cause the waste particles to be recirculated through theenginelubricationsystemwiththenewoil.

Drain the Engine Lubricating Oil

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

enough to collect the waste oil.

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

Remove the container and disposal of the waste oil in accordance with local regulations.

Replace the Oil Filter

NOTICE Perkins oil ﬁlters are manufactured to Perkins speciﬁcations.Useofanoilﬁlter 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. Place a suitable container below the oil ﬁlter

assembly. Remove the oil ﬁlter with a suitable tool.

98 SEBU8605-01 Maintenance Section Engine Oil and Filter - Change

Illustration 65

g02131364

2. Clean sealing surface (1).

3. Apply clean engine oil to O ring seal (2) for the

new oil ﬁlter (3).

Horizontal Oil

Illustration 66

Filter

g02132333

1. Place a suitable container below the oil ﬁlter

assembly. Remove the drain plug (1) and allow the oil to drain.

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.

4. Install the new oil ﬁlter (3). Spin on the oil ﬁlter

until the O ring contacts the sealing surface (2). Then rotate the oil ﬁlter ¾ of a full turn. Remove the container and disposal of the waste oil in accordance with local regulations.

2. Remove the oil ﬁlter with a suitable tool.

Note: The following actions can be carried out as

part of the preventive maintenance program.

3. 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.

Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil ﬁlter element. Ferrous metals may indicate wear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on the aluminum parts, brass parts, or bronze parts of the engine. Parts that may be affected include the following items: main bearings, rod bearings, and turbocharger bearings.

Due to normal wear and friction, it is not uncommon to ﬁnd small amounts of debris in the oil ﬁlter.

4. Install the drain plug (1) and tighten to a torque of 12 N·m (106 lb in).

5. Clean the sealing surface (2).

SEBU8605-01 99

Maintenance Section

Fan Clearance - Check

NOTICE Do not ﬁll the o This oil would not be ﬁltered and could be contaminated. Contaminated oil can cause accelerated wear to engine compon

6. Apply clean engine oil to O ring seal (3) for the

new oil ﬁlte

7. Install the new oil ﬁlter. Spin on the oil ﬁlter (4)

until the O r Then rotate the oil ﬁlter ¾ of a full turn. Remove the container and disposal of the waste oil in accordanc

Fill the Oi

1. Remove the oil ﬁller cap. Refer to this

Operatio Recommendations” for more information on suitable oils. Fill the oil pan with the correct amount o to this Operation and Maintenance Manual, “Reﬁll Capacities” for more information on reﬁll capacit

il ﬁlters with oil before installing them.

ents.

r(4).

ing contacts the sealing surface (2).

e with local regulations.

lPan

n and Maintenance Manual, “Fluid

f new engine lubricating oil. Refer

ies.

4. Remove the engi check the oil level. Maintain the oil level between “L” and “H” marks on the engine oil level gauge. Do not ﬁll the c

Fan Clearanc

There are different types of cooling systems. Refer to the OEM for information on clearance for the fan.

Ensure that the engine is stopped. Ensure that the cooling system is full. The clearance between the cover (1) a gap (A) between the edge of the cover and the tip of the fan blade must be checked in four equally spaced positions

nd the fan (2) will require checking. The

ne oil level gauge in order to

rankcase above the “H” mark.

i04323342

e - C heck

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

2. Start the engine and run the engine at “LOW

IDLE” for 2 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 10 minutes.

Illustration 67

“L” Low

“H” High

g02173847

100 SEBU8605-01 Maintenance Section Fuel System - Prime

Illustration 68

Typical example

Adjustment of the cover will change the clearance (gap) between the edge of the cover and the tip of the fan blade. Ensure that the cover is centralized to the fan.

The maximum clearance is 18 mm (0.71 inch). The minimum clearance is 10 mm (0.39 inch).

i03906114

Fuel System - Prime

Note: Refer to Systems Operation, Testing, and Adjusting, “Cleanlines s 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.

g02479476

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.

•

The fuel ﬁlter has been replaced.

•

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

Perkins Engine 1204E-E44TA, 1204E-E44TTA Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual