Perkins Engine 1206E-E66TA Service Manual

Operation and
Maintenance
Manual

SEBU8603-01

May 2011

1206E-E66TA Industrial Engine

BK (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.

SEBU8603-01 3

Table of Contents

Table of Contents

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

Safety Section

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

General Haz ard Information ................................... 8

Burn Prevention ..................................................... 11

Fire Prevention and Explosion Prevention ............ 12

Crushing Prevention and Cutting Prevention ........ 14

Mounting and Dismounting ................................... 14

High Pre ssure Fuel Lines ..................................... 14

Before Starting Engine .......................................... 16

Engine Starting ..................................................... 16

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

Maintenance In

Warranty Sect

Warranty Information ........................................... 110

terval Schedule ............................ 78

ion

Reference Information Section

Reference Materials ............................................. 114

Index Section

Index .................................................................... 115

Electrical System .................................................. 17

Engine Electronics ................................................ 18

Product Information Section

Model Views ......................................................... 20

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

Operation Section

Lifting and Storage ................................................ 29

Gauges and Indicators .......................................... 32

Features and Controls .......................................... 34

Engine Diagnostics ............................................... 45

Engine Starting ..................................................... 51

Engine Operation .................................................. 54

Engine Stopping ................................................... 56

Cold Weathe r Operation ....................................... 58

Maintenance Section

Refill Capacities .................................................... 62

Maintenance Recommendations .......................... 76

4 SEBU8603-01
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.

SEBU8603-01 5

Safety Section

Safety Messages

Safety Section

i04220089

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 font
right side of the valve mechanism cover and located
onthesideoft

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

T

g01154807

6 SEBU8603-01
Safety Section
Safety Messages

Illustration 2

Typical example

(1) Universal warning

(2) Hand (High Pressure)

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

g02382617

SEBU8603-01 7

Safety Section

Safety Messages

Illustration 3

Typical example

The warning label for the Hand (High Pressure)
(3) is a wrap around label that is installed on the
high-pressure fuel line.

g02382677

Illustration 4

ical example

Typ

her Warning

Et

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

ersonal injury.

p

g02382618

8 SEBU8603-01
Safety Section
General Hazard Information

Illustration 5

Typical example

An ether warning label will be installed on the air
cleaner or close to the air cleaner. The location will
depend on the application.

g01154809

i03566024

General Hazard Information

Vent the engine

•

engine is operated in an enclosed area.

If the engine i

•

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

Wear a hard hat, protective glasses, and other

•

protective

When work is performed around an engine that is

•

operating,
to help prevent damage to hearing.

Do not wear

•

on controls or on other parts of the engine.

Ensure tha

•

securedinplaceontheengine.

Never put

•

Glass containers can break.

Use al l cl

•

Report all necessary repairs.

•

eaning solutions with care.

exhaust to the outside when the

s not running, do not release the

d.

equipment, as required.

wear protective devices for ears in order

loose clothing or jewelry that can snag

t all protective guards and all covers are

maintenance fluids into glass containers.

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.

Tampering with the engine installation or tampering

•

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

g00104545

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

The engine is stopped. Ensure that the engine can

•

not be started.

The protective locks or the controls are in the

•

applied position.

Engage the secondary brakes or parking brakes.

•

the vehicle or restrain the vehicle before

Block

•

maintenance or repairs are performed.

onnect the batteries when maintenance

Disc

•

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

the leads in order to help prevent sparks.

Tap e

Disconnect the connector for the unit injector that

•

ocated on the valve cover base. This will help

is l
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

•

e engine while the engine is operating.

th

Do not attempt any repairs that are not understood.

•

e the proper tools. Replace any equipment that

Us
is damaged or repair the equipment.

SEBU8603-01 9

Safety Section

General Hazard Information

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 o r 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

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 c lea

•

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.

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.

When work is performed around an engine that is

•

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

ugs

lly loosen, but do not remove the last two

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

g00702020

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
275 kPa (40 psi).

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.

10 SEBU8603-01
Safety Section
General Hazard Information

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 Spill age

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
bound in a resin or sealed in some way. 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

lutchplates,andsomegaskets.The

s not hazardous unless airborne dust that

t may contain asbestos is present, there

compressed air for cleaning.

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.

Asbestos Information

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

Illustration 9

g00702022

SEBU8603-01 11

Safety Section

Burn Prevention

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

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 sul-

4

fur 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 pe rsonal 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.

i04224009

Burn Preve nti on

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 cause 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.

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
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.

Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the

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.

r cap. The filler cap must be cool enough to touch

skin, the eyes, or the mouth.

s

rsonal injury. Do not allow hot oil to contact the

12 SEBU8603-01
Safety Section
Fire Prevention and Explosion Prevention

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

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.

Determine whether the engine will be operated in an
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.

g00704000

Store fuels and
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. D
storing flammable materials.

Do not expose

Exhaust shields (if equipped) protect hot exhaust
components
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

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
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all elect

Eliminate all wiring that is unattached or unnecessary.
Do not us
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.

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

Contact with high pressure fuel may cause fluid
pene
el spray may cause a fire hazard. Failure to fol­low these inspection, maintenance and service in­stru

After the engine has stopped, you must wait for 10
min
purged from the high pressure fuel lines before any
service or repair is performed on the engine fuel lines.

rical connections.

ined battery cables will help to prevent arcing

tration and burn hazards. High pressure fu-

ctions may cause personal injury or death.

utes in order to allow the fuel pressure to be

lubricants in correctly m arked

onotsmokeinareasthatareusedfor

theenginetoanyflame.

from oil or fuel spray in case of a line,

uid. Clean any such lines or tanks

electrical wires daily. Repair any wires

e any wires or cables that are smaller than

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.

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.

m

SEBU8603-01 13

Safety Section

Fire Prevention and Explosion Prevention

Illustration 12

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

g00704059

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

Do not charge a frozen battery. 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

Donotbendhighpressurelines.Donotstrikehigh
pressure lines. Do not install any lines that are
damaged

.

Illustration 13

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.

g00704135

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

Replace the parts if any of the following conditions
are pre

High pressure fuel line or lines are removed.

•

End fittings are damaged or leaking.

•

Outer

•

Wires are exposed.

•

Outer coverings are ballooning.

•

Flex

•

Outer covers have embedded armoring.

•

End fittings are displaced.

•

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

erkins distributor for replacement parts.

sent:

coverings are chafed or cut.

ible part of the hoses are kinked.

e sure that all clamps, guards, and heat shields

ts, and excessive heat.

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

14 SEBU8603-01
Safety Section
Crushing Prevention and Cutting Prevention

i02143194

Crushing Prevention and
Cutting Preve

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

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

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

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

ve the guards in place until maintenance

ntion

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

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

be injured by flying debris.

i04016709

Mounting and Dismounting

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.

i03550790

h Pressure Fue l 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 cause personal injury or death.

s

SEBU8603-01 15

Safety Section

High Pressure Fuel Lines

Illustration 14

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

(4) High press ure line
(5) High press ure line
(6) High press ure line

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

This is because of the following items:

The high pressure fuel lines are constantly charged

•

with high pressure.

The internal pressures of the high pressure fuel

•

lines are higher than other types of fuel system.

The high pressure fuel lines are formed to shape

•

and then strengthened by a special process.

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

Do not check the high pressure fuel lines with the
engine or the starting motor in operation. 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.

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

g01877473

(7) High pressure fuel manifold (rail)
(8) High pressure line
(9) Fuel transfer line th at is high pressure

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

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

Inspect the high pressure fuel lines for damage,

•

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

Donotoperatetheenginewithafuelleak.Ifthere

•

is a leak do not tighten the connection in order
to stop the leak. The connection must only be
tightened to the recommended torque. Refer to
Disassembly and Assembly, “Fuel injection lines ­Remove and Fuel injection lines - Install”.

Ifthehighpressurefuellinesaretorquedcorrectly

•

and the high pressure fuel lines are leaking the
high pressure fuel lines must be replaced.

Ensure that all clips on the high pressure fuel lines

•

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 replaced. Refer to Disassembly and
assembly manual, “ Fuel Injection Lines - Install”.

16 SEBU8603-01
Safety Section
Before Starting Engine

i02813489

Before Starting Engine

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

Overspeed s
engines that are controlled electronically. If automatic
shutdown does not occur, press the emergency stop
buttonino

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 fr

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

All prot
be installed if the engine must be started in order
to perform service procedures. To help prevent an
acciden
around the parts carefully.

Do not b
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The

its are also provided in order to help prevent

circu
engine damage.

e Service Manual for repairs and for

See th
adjustments.

tial start-up of an engine that is new,

hed by shutting off the air and/or fuel

hutdown should occur automatically for

rder to cut the fuel and/or air to the engine.

ee of personnel.

suitable for the conditions. Ensure that all

ective guards and all protective covers must

t that is caused by parts in rotation, work

ypass the automatic shutoff circuits. Do not

i03996487

Engine Starting

All protective
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that
around the parts carefully.

Start the eng
from the engine start switch.

Always star
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Kn
to prevent major damage to the engine components.
Knowing that the procedure will also help to prevent
personal i

To ensure that the jacket water heater (if equipped)
and/or the
correctly, check the water temperature gauge. Also,
check the oil temperature gauge during the heater
operatio

Engine exhaust contains products of combustion
which can
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the

Note: The engine is equipped with a device for cold

g. If the engine will be operated in very cold

startin
conditions, then an extra cold starting aid may be
required. Normally, the engine will be equipped with
the cor
operation.

These
aid in each individual cylinder that heats the intake air
in order to improve starting. Some Perkins engines
may ha
the ECM that allows a controlled flow of ether into
the engine. The ECM will disconnect the glow plugs

re the ether is introduced. This system would

befo
be installed at the factory.

guards and all protective covers must

is caused by parts in rotation, work

ine from the operators compartment or

t the engine according to the procedure

owing that the correct procedure will help

njury.

lube oil heater (if equipped) is working

n.

be harmful to your health. Always start the

engine exhaust to the outside.

rect type of starting aid for your region of

engines are equipped with a glow plug starting

ve a cold starting system that is controlled by

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

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

i02234873

Engine Stopp ing

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

SEBU8603-01 17

Safety Section

Electrical System

Use the Emergen

cy Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency sto

p, DO NOT start the engine until the
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 bee

n overhauled.

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

engine and/or shutting off the air supply

to the engine.

i04193189

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.

Grounding Practices

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 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

g02383098

18 SEBU8603-01
Safety Section
Engine Electronics

Illustration 16

example

Typical

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

Correct grounding for the engine electrical system
is necessary for optimum engine performance

liability. Incorrect grounding will result in

and re
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.

g02383099

The power suppl
connections for the engine electronics should always
be from the isolator to the battery.

y connections and the ground

i03642610

Engine Electro nics

Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
andcouldr
engine damage.

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

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

The following actions are available for engine
monitoring control:

esult in personal injury or death and/or

Uncontrolled electrical circuit paths can result in
damage to the crankshaft bearing journal surfaces
and to

Engines that are installed without engine-to-frame
grou
discharge.

To e n
systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be
use
engine ground to the frame.

The
free of corrosion. The engine alternator must be
grounded to the negative “-” battery terminal. The
gr
charging current of the alternator.

aluminum components.

nd straps can be damaged by electrical

surethattheengineandtheengineelectrical

d. This path may be provided by way of a direct

connections for the grounds should be tight and

ounding wire must be adequate to handle the full

Warning

•

Derate

•

Shutdown

•

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

Engine Coolant Temperature

•

Engine Oil Pressure

•

Engine Speed

•

Intake Manifold Air Temperature

•

Engine Intake Throttle Valve Fault

•

Wastegate Regulator

•

SEBU8603-01 19

Safety Section

Engine Electronics

Supply Voltage

•

Fuel Pressure in Manifold (Rail)

•

NOx Reduction System

•

Engine After

•

The Engine Monitoring package can vary for different
engine mode
However, the monitoring system and the engine
monitoring control will be similar for all engines.

Note: Many of the engine control systems and display
modules that are available for Perkins Engines will
work in uni
Together, the two controls will provide the engine
monitoring function for the specific engine application.
Refer to Tr
Engine Monitoring System.

son with the Engine Monitoring System.

oubleshooting for more information on the

to Sensors

treatment System

ls and different engine applications.

20 SEBU8603-01
Product Information Section
Model Views

Product Information
Section

Model Views

i04171351

Model View Illustrations

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

Engine views

Illustration 17

Typical example

(1) Secondary fuel filter
(2) Crankcase breather
(3) E lectronic control module (ECM)
(4) Oil sampling valve

(5) Fuel strainer
(6) Oil fi lter
(7) Fuel priming pump
(8) Oil gauge (Dipstick)

g02361696

(9) Primary fuel filter
(10) High-pressure fuel pump

SEBU8603-01 21

Product Information Section

Model Views

The location of

the in-line strainer (5) and the priming

pump (7) will depend on the application.

Illustration 18

Typical example

(11) Rear lifting eye
(12) NOx reduction system (NRS)
(13) Front lifting eye
(14) Turbocharger

(15) Back pressure valve
(16) E ngine oil pan (Sump)
(17) Starting motor
(18) Engine oil drain plug

g02361697

(19) Flywheel housing
(20) Flywheel
(21) Exhaust outlet
(22) Exhaust gas cooler

22 SEBU8603-01
Product Information Section
Model Views

Illustration 19

Typical example

(23) Belt
(24) Connection for air inlet
(25) Outlet connection for the coolant
(26) Water temperature regulator housing

(Thermostat housing)

(27) Water pum p
(28) Oil filler
(29) Inlet connection for the Coolant
(30) Vibration damper
(31) Belt tensioner

g02379457

(32) Alternator

SEBU8603-01 23

Product Information Section

Model Views

Illustration 20

example

Typical

(33) Coolant drain plug for c ylinder block
(34) Coolant drain plug for exhaust gas

cooler

g02381218

24 SEBU8603-01
Product Information Section
Model Views

Engine Aftertreatment System

Illustration 21

Typical example

an emissions module (CEM)

(1) Cle

et connection

(2) Inl

Engin

e Description

(3) Out
(4) Mou

let connection

nting cradle

i04340730

The Perkins 1206-E66 Industrial Engine has the
following characteristics.

In-line Six cylinder

•

rstrokecycle

Fou

•

Turbocharged charge cooled

•

Engine Specifications

Note: The front end of the engine is opposite the

flywheel end of the engine. The left and the right

des of the engine are determined from the flywheel

si
end. The number 1 cylinder is the front cylinder.

(5) Fle

Illustration 22

Cylinder and valve location

(A) Exhaust valves
(B) Inlet valves

xible exhaust pipe from engine to

CEM

560

g02384

g01127295

SEBU8603-01 25

Product Information Section

Model Views

Table 1

Engine Specifications

Operating Range (rpm) 900 to 2800

Number of Cylinders 6 In-Line

Bore

Stroke 127 mm (5 inch)

Power

Aspiration Turbocharged charge

Compression Ratio 16.5:1

Displacement

Firing Order

Rotation (flywheel end) Counterclockwise

(1)

The operating rpm is dependent on the engine rating, the

application, and the configuration of the throttle.

105 mm (4.13

129.4 kW (173.52 hp)

cooled

6.6 L (402

1-5-3-6-2-4

(1)

inch)

.7 cubic inch)

Electronic Engine Features

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

Engine Diagn ostics

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

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

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

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

ngine rpm.

Engine Co

The cooling system and lubrication system consists
of the fo

•

•

llowing components:

Gear-driven centrifugal water pump

Water temperature regulator which regulates the
engine coolant temperature

built-in diagnostics in order to ensure

. Under certain conditions, the engine

ic codes.

event.

or additional information, refer to

oling and Lubrication

Engine monitoring

•

Engine speed governing

•

Control of the injection pressure

•

Cold start strategy

•

Automatic air/fuel ratio control

•

To rque rise shaping

•

Injection timing control

•

System diagnostics

•

Low temperature regeneration

•

For more information on electronic engine features,
refer to the Operation and Maintenance Manual,
“Features and Controls” topic (Operation Section).

Gear-driven rotor type oil pump

•

Oil coo

•

The engine lubricating oil is supplied by a rotor type
oil pu
engine lubricating oil is filtered. The bypass valve
can provide unrestricted flow of lubrication oil to
the en
plugged.

Engi
engine performance depend on adherence to proper
operation and maintenance recommendations.
Engi
the use of recommended fuels, lubrication oils, and
coolants. Refer to this Operation and Maintenance
Man
information on maintenance items.

ler

mp. The engine lubricating oil is cooled and the

gine if the oil filter element should become

ne efficiency, efficiency of emission controls, and

ne performance and efficiency also depend on

ual, “Maintenance Interval Schedule” for more

Aftertreatment System

e aftertreatment system is approved for use by

Th
Perkins. In order to be emission-compliant only the
approved Perkins aftertreatment system must be

ed on a Perkins engine.

us

26 SEBU8603-01
Product Information Section
Model Views

Clean Emission

The CEM comprises of two main components in a
single unit, t
the Diesel Particulate Filter DPF. The function of the
CEM is to ensure that the engine exhaust meets
the required
operation.

Theenginee
the CEM. The exhaust gases pass through the DOC
in order to remove contaminants, carbon monoxide,
and hydroca
DPF where any particulate matter soot and ash will
be trapped.

The CEM uses a passive regeneration process to
ensure that normal operation of the engine removes
the soot. T
which the soot is captured. The ash remains in the
DPF and must be removed at an engine overhaul.

he Diesel Oxidation Catalyst DOC and

emissions regulation for the country of

xhaust is connected by a flexible pipe to

rbons. The exhaust gases then enter the

he soot is removed at an equal rate of

Module (CEM)

Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operati
addition, use recommended fuels, coolants, and
lubricants. Use the Operation and Maintenance
Manual a

on and maintenance recommendations. In

s a guide for required engine maintenance.

Expected engine life is generally predicted by the
averag
that is demanded is based on fuel consumption of
the engine over a period of time. Reduced hours of
opera
throttle settings result in a lower average power
demand. Reduced hours of operation will increase
the le
overhaul is required. For more information, refer to
the Operation and Maintenance Manual, “Overhaul
Cons

Afte

e power that is demanded. The average power

tion at full throttle and/or operating at reduced

ngth of operating time before an engine

iderations” topic (Maintenance Section).

rmarket Products and Perkins

Engines

Perkins does not warrant the quality or performance
of non-Perkins fluids and filters.

When auxiliary devices, accessories, or consumables
(filters, additives, catalysts,) which are made by other

ufacturers are used on Perkins products, the

man
Perkins warranty is not affected simply because of
such use.

However, failures that result from the installation
or use of other manufacturers devices,

cessories, or consumables are NOT Perkins

ac
defects. Therefore, the defects are NOT covered
under the Perkins warranty.

SEBU8603-01 27

Product Information Section

Product Identification Information

Product Identification
Information

i03865704

Plate Locations and Film
Locations
(Engine Aftertreatment System
)

Illustration 23

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 24

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.

i03867276

Reference Num bers

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

Record for Reference

Engine Model _______________________________________________

28 SEBU8603-01
Product Information Section
Product Identification Information

Engine Serial n

umber

_____________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

_________________________________________

Primary Fuel

Filter

Water Separator Element ________________________________

Secondary Fuel Filter Element __________________________

Lubricatio

n Oil Filter Element

___________________________

Auxiliary Oil Filter Element _______________________________

Total Lubrication System Capacity _____________________

Total Cool

ing System Capacity

_________________________

Air Cleaner Element ______ _________________________________

Drive Belt ____________________________________________________

Engine A

ftertreatment System

Part Number ________________________________________________

Serial Number _______ _______________________________________

i04274850

Emissions Certification Film

An emission label is installed on the front gear cover.

Note: Asecondemissionlabelwillbesuppliedwith
the engine. If necessary, the second emission label

e installed on the application by the original

will b
equipment manufacturer.

Illustration 25

Typical exa mple

g02443596

SEBU8603-01 29

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

Product Lifting
(Engine)

i03977851

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 26

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

30 SEBU8603-01
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 27

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 27.

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”.

r

SEBU8603-01 31

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.

n.

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

32 SEBU8603-01
Operation Section
Gauges and Indicators

Gauges and Ind icators

i04220531

Gauges and Indicators

0

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

SEBU8603-01 33

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

•

ps

•

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.

p

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

Ev

Coolant temperature

Oil temperature

34 SEBU8603-01
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

y.

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.

SEBU8603-01 35

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

36 SEBU8603-01
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.

SEBU8603-01 37

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 28

(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

i04220589

Sensors and Electrical
Components

The Illustration within the section shows the typical
locations of the sensors for a 1206E-66 Industrial
Engine. Specific engines may appear different from
the illustration due to differences in applications.

38 SEBU8603-01
Operation Section
Features and Controls

Illustration 29

Typical example

(1) Coolant Temperature Sensor
(2) Wastegate Regulator
(3) Throttle valve
(4) Fuel Pressure Sensor (Fuel Rail

Pressure Sensor)

(5) Intake Manifold Air Temperature Sensor

(6) Intake Manifold Pressure Sensor
(7) Diagnostic Conn ector
(8) Electronic Control Module (ECM)
(9) Atmospheric Pressure Sensor

(Barometric Pressure Sensor)

(10) Primary Speed/Timing Sensor

Note: The location of the secondary fuel filter, the
primary fuel filter, and the fuel priming pump will
depend on the application. These locations will affect
items (12, and 13).

g02392837

(11) Oil Pressure Sensor
(12) Fuel Priming Pump
(13) Water in Fuel Sw itch
(14) Fuel Temperature Sensor
(15) Solenoid for the H igh Pressure Fuel

Pump

SEBU8603-01 39

Operation Section

Features and Controls

Illustration 30

Typical example

(16) Inlet Pressure Sensor for the NOx

Reduction S ystem (NRS)

(17) Outlet Pressure sensor for the NRS

(18) Control Valve for the NRS
(19) Temperature Sensor for the NRS
(20) Alternator

g02392856

(21) Back Pressure Valve
(22) Secondary Speed/Timing Sensor
(23) Starter Motor

40 SEBU8603-01
Operation Section
Features and Controls

Illustration 31

Typical example

(1) Coolant Temperature Sensor (2) Wastegate Regulator (3) Throttle valve

g02394156

Illustration 32

Typical example

(4) Fuel Pressure Sensor (Fuel Rail

Pressure Sensor)
(5) Intake Manifold Air Temperature Sensor
(6) Intake Manifold Pressure Sensor

(7) Diagnostic Conn ector
(8) Electronic Control Module (ECM)
(9) Atmospheric Pressure Sensor

(Barometric Pressure Sensor)

g02394157

(10) Primary Spee d/Timing Sensor
(11) Oil Pressure Sensor
(12) Fuel Priming Pump

SEBU8603-01 41

Operation Section

Features and Controls

Illustration 33

example

Typical

(13) Water in Fuel Switch
(14) Fuel Temperature Sensor
(15) Solenoid for the High Pre ssure Fuel Pum p

g02395396

42 SEBU8603-01
Operation Section
Features and Controls

Illustration 34

example

Typical

(16) Inlet Pressure Sensor for the NOx

Reduction S ystem (NRS)

(17) Outlet Pressure sensor for the NRS
(18) Control Valve for the NRS

g02395399

(19) Temperature Sensor for the NRS

SEBU8603-01 43

Operation Section

Features and Controls

Illustration 35

example

Typical

(20) Alternator
(21) Back Pressur e Valve
(22) Secondary Speed/Timing Sensor
(23) Starter Motor

2685

i0437

Engine Shutoffs and Engine
Alarm

Shutoffs

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

Shutoffs are set at critical levels for the following

ms:

ite

Operating temperature

•

Operating pressure

•

s

rolled by the ECM.

g02395417

The particular shutoff may need to be reset before
theenginewillstart.

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

Be familiar with the following items:

Types and locations of the shutoff

•

Conditions which cause each shutoff to function

•

The resetting procedure that is required to restart

•

the engine

Alarms

erating level

Op

•

Operating rpm

•

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

44 SEBU8603-01
Operation Section
Features and Controls

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

Your engine m
sensors or switches:

Coolant lev

indicates when the coolant level is low.

Coolant tem

sensor indicates high jacket water coolant
temperature.

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

Intake ma nifold pressure – The intake manifold
pressure
engine manifold.

Fuel rail

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

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

Engine overspeed – If the engine rpm exceeds the
oversp

Air filter restriction – The switch checks the air
filter

User-Defined switch – This switch can shut down
the en

ature.

sensor checks the rated pressure in the

pressure – The fuel rail pressure sensor

ressure, at a set engine speed.

eed setting, the alarm will be activated.

when the engine is operating.

gine remotely.

rated by a sensor or by a switch.

Mwillsendasignalinorderto

ay be equipped with the following

el – The low coolant level switch

perature – The coolant temperature

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

easures are not taken within a

eed to be reset.

Testing

TurningthekeyswitchtotheONpositionwillcheck
the indicato
indicator lights will be illuminated for 2 seconds after
the keyswitch is operated. Replace suspect bulbs
immediatel

Refer to Troubleshooting, KENR9116 for more
informatio

r lights on the control panel. All the

y.

n.

i03554501

Overspeed

ECM ______________________Electronic Control Module

•

RPM ____

•

An overspeed is detected by the speed/timing
sensors

Thedefaultsettingforanoverspeedis3000rpm.
The ECM
injectors, until the rpm drops below 200 rpm of the
overspeed setting. A diagnostic fault code will be
logged
indicate a diagnostic fault code.

An ove
This setting depends on the application.

____________________

.

will cut the power to the electronic unit

into the ECM memory and a warning lamp will

rspeed can be set from 2600 rpm to 3000 rpm.

Revolutions Per Minute

Water in fuel switch – This switch checks for water

e primary fuel filter when the engine is operating.

in th

Fuel temperature – The fuel temperature sensor

tors the pressurized fuel in the high-pressure

moni
fuel pump.

e: The sensing element of the coolant

Not

temperature switch must be submerged in coolant
in order to operate.

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

nditions occur.

co

TICE

NO
When an alarm is activated, corrective measures must
be taken before the situation becomes an emergency

n order to avoid possible engine damage.

i

SEBU8603-01 45

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)

46 SEBU8603-01
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

15

4

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.

SEBU8603-01 47

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.

48 SEBU8603-01
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)

SEBU8603-01 49

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)

50 SEBU8603-01
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

C

SEBU8603-01 51

Operation Section

Engine Starting

Engine Starting

i03648917

Before Starting Engine

Perform the
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can
help preve
Operation and Maintenance Manual, “Maintenance
Interval Schedule” for more information.

Ensure that the engine has an adequate fuel

•

supply.

Open the fuel supply valve (if equipped).

•

All valv
supply lines must be open. Damage to the fuel system
can occure if fuel lines are closed with the engine in
operat

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”.

required daily maintenance and other

nt major repairs at a later date. Refer to the

NOTICE

es in the fuel return line must be open and fuel

ion.

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

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.

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.

e operating period of the warning light for

w the starting motor to cool before attempting to

justtheenginespeedcontrolduring

he glow plugs is extinguished.

NOTICE

ine exhaust contains products of combustion

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

d, if in an enclosed area, vent the exhaust to the

an
outside.

not start the engine or move any of the controls

Do

•

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

othecontrols.

t

Reset all of the shutoffs or alarm components.

•

Ensure that any driven equipment has been

•

disengaged. Minimize electrical loads or remove
any electrical loads.

w the keyswitch to return to the RUN position

4. Allo
after the engine starts.

5. Rep

eat step 2 through step 4 if the engine fails

to start.

i03570564

Cold Weather Starting

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

52 SEBU8603-01
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.

SEBU8603-01 53

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

54 SEBU8603-01
Operation Section
Engine Operation

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.

s

SEBU8603-01 55

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.

56 SEBU8603-01
Operation Section
Engine Stopping

Engine Stopping

i02334873

Stopping the Engine

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

Avoid accelerating the engine prior to shutting it down.

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

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

1. Remove the load from the engine. Reduce the

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

2. Stop the engine after the cool down period

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

i01903586

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.

SEBU8603-01 57

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.

58 SEBU8603-01
Operation Section
Cold Weather Operation

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.

SEBU8603-01 59

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.

p

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.

di

60 SEBU8603-01
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

SEBU8603-01 61

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.

e.

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

p.

pum

For more information about fuel heaters (if equipped),

fer to the OEM information.

re

62 SEBU8603-01
Maintenance Section
Refill Capacities

Maintenance Section

Refill Capacities

i03995972

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)

These values are the approx imate capacities for the crankcase
oil sump (aluminum) which includes the standard factory
installed oil filters. Engines with auxiliary oil filters will require
additional oil. Refer to the OEM specifications for the capacity
of the aux iliary oil filter. The design of the oil pan can change
the oil capacity of the oil pan.

(1)

Cooling System

Minimum Maximum

13.5 L

(3.56 US

gal)

16.5 L

(4.36 US

gal)

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

NOTICE
Frequen
proper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

•

•

•

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

tlycheckthespecific gravity of the coolant for

Contamination of the cooling system

Overheating of the engine

Foaming of the coolant

NOTICE

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

Table 7

Engine

Refill Capacities

Compartment or System

Engine Only

External System Per OEM

(1)

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

(1)

Liters

15 L

3.96 US gal)

(

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

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

Coolant is normally composed of three elements:
Water, additives, and glycol.

Water

Waterisusedinthecoolingsysteminorderto
transfer heat.

SEBU8603-01 63

Maintenance Section

Refill Capacities

Distilled wate
recommended for use in engine cooling systems.

DO NOT use the f
systems: Hard water, softened water that has been
conditioned with salt, and sea water.

If distilled water or deionized water is not available,
use water with the properties that are listed in Table 8.

Table 8

Property Maximum Limit

Chloride (Cl) 40 mg/L

Sulfate (SO4) 100 mg/L

Total Hardness 170 mg/L

Total Solids 340 mg/L

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

Local water utility company

•

Agricultural agent

•

Independent laboratory

•

r or deionized water is

ollowing types of water in cooling

Acceptable

Acidity pH of 5.5 to 9.0

Water

Additives

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

Corrosion

•

Formation of mineral deposits

•

Rust

•

Scale

•

Foaming of the coolant

•

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

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

Formation of gel compounds

•

Reduction of heat transfer

•

Plugging of rad

•

iators, coolers, and small passages

Glycol

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

Boiling

•

Freezing

•

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

Table 9

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

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

er, ethylene and propylene glycol provide

Ethylene Glycol

Concentration Freeze Protection

50 Percent −36 °C (−33 °F)

60 Percent

NOTICE

Propylene Glycol

Concentration Freeze Protection

50 Percent −29 °C (−20 °F)

−51 °C

(−60 °F)

Coolant Recommendations

ELC____________________________ Extended Life Coolant

•

SCA___________________ Supplement Coolant Additive

•

Leakage of the water pump seal

•

64 SEBU8603-01
Maintenance Section
Refill Capacities

ASTM_________

•

_________________________________

American

Society for Testing and Materials

The following

two coolants are used in Perkins diesel

engines:

Preferred – P

erkins 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.

s recommends a 1:1 mixture of water and

Perkin
glycol. This mixture of water and glycol will provide
optimum heavy-duty performance as an antifreeze.
This ra

tiomaybeincreasedto1:2watertoglycolif

extra freezing protection is required.

ure of SCA inhibitor and water is acceptable but

Amixt
will not give the same level of corrosion, boiling and,
freezing protection as ELC. Perkins recommends a 6

nt to 8 percent concentration of SCA in those

perce
cooling systems. Distilled water or deionized water
is preferred. Water which has the recommended

erties may be used.

prop

Table 11

Coolant Service Life

Coolant Type Service Life

Perkins ELC

mmercial Heavy-Duty

Co

Antifreeze that meets

“ASTM D6210”

Commercial SCA inhibitor

and Water

(1)

Use the interval that occurs first. The cooling system must

also be flushed out at this time.

6,000 Service Hours or

Three Years

3000 Service Hours or

3000 Service Hours or

oYear

Tw

One Year

(1)

ELC

Perkins provides ELC for use in the following
applications:

Heavy-duty die

•

Automotive applications

•

sel engines

The anti-corrosion package for ELC is different from
the anti-corrosion package for other coolants. ELC
is an ethylen

e glycol base coolant. However, ELC
contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrite. Perkins ELC
has been for

mulated 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 provid

es 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
recommend

ed for topping off the cooling system.

Containers of several sizes are available. Consult
your Perk

ELC Cooli

ins distributor for the part numbers.

ng 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 recommendations can reduce cooling sys­tem components life unless appropriate corrective ac­tion is performed.

der to maintain the correct balance between

In or
the antifreeze and the additives, you must maintain
the recommended concentration of ELC. Lowering

roportion of antifreeze lowers the proportion of

the p
additive. This will lower the ability of the coolant to
protect the system from pitting, from cavitation, from

sion, and from deposits.

ero

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

Do not use standard supplemental coolant additive
(SCA).

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

Heavy-duty spark ignited gas engines

•

SEBU8603-01 65

Maintenance Section

Refill Capacities

ELC Cooling Sys

Note: If the cooling system is already using ELC,

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

Clean water
when ELC is drained from the cooling system.

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

ts are not required to be used at

d by the addition of some other type of

is the only cleaning agent that is required

ooling system is filled, the heater control

g system is drained and the cooling system

oolant level stabilizes. As needed, add

tem Cleaning

Changing to Perkins ELC

To c h an g
ELC, perform the following steps:

efromheavy-dutyantifreezetothePerkins

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

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

7. Drain the co

and flushthecoolingsystemwithcleanwater.

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

8. Repeat St

system is completely clean.

9. Fill the

ELC.

ncomplete flushing of the cooling system

ush the system until all the signs of the

oling system into a suitable container

ooling system cleaner must be thoroughly

he cleaner may also corrode the cooling

eps 6 and repeat steps 7 until the

coolingsystemwiththePerkinsPremixed

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

Dispose of all fluids according to local regulations and
mandates.

1. Drai

2. Dispose of the coolant according to local

3. Flush the system with clean water in order to

4. Use an appropriate cleaner to clean the system.

5. Drain the cleaner into a suitable container. Flush

6. Fill the cooling system with clean water and

st be taken to ensure that all fluids are

t. Be prepared to collect the fluidwithsuitable

n the coolant into a suitable container.

lations.

regu

ove any debris.

rem

low the instruction on the label.

Fol

e cooling system with clean water.

th

erate the engine until the engine is warmed to

op
49° to 66°C (120° to 150°F).

ELC Cool

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.

ing System Contamination

NOTICE

66 SEBU8603-01
Maintenance Section
Refill Capacities

Commercial Hea

vy-Duty Antifreeze and

SCA

NOTICE
Commercial Heavy-Duty Coolant which contains
Amine as part of the corrosion protection system must
not be used.

NOTICE
Never opera

te an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
correct op

erating 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

ometer for checking the glycol concentration.

refract
A hydrometer should not be used.

Perkins

engine cooling systems should be tested at

500 hour intervals for the concentration of SCA.

ons of SCA are based on the results of the test.

Additi
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

misinitiallyfilled.

syste

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.

Table13isanexampleforusingtheequationthat
is in Table 12.

Table 13

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant At The Initial Fill

otal Volume

T

of the Cooling

System (V)

15 L (4 US gal)

Coolant At The Initial Fill

V × 0.045 = X

ultiplication

M

Factor

×0.045

Amount of

SCA that is

Required (X)

0.7 L (24 oz)

Adding The SCA t

o The Heavy-Duty

Coolant For Maintenance

Heavy-duty an
additions of an SCA.

Tes t t he a nt i
of SCA. For the interval, refer to the Operation
and Maintenance Manual, “Maintenance Interval
Schedule” (
Supplemental Coolant Additive (SCA) Test/Add.

Additions o
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

V is the total volume of the cooling system.

X is the amount of SCA that is required.

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

Table 15

Example Of The Equation For Adding The SCA To

The Hea

Total Volume

of the Cooling

Syste

15 L (4 US gal) × 0.014 0.2 L (7 oz)

tifreeze of all types REQUIRE periodic

freeze periodically for the concentration

Maintenance Section). Cooling System

f SCA are based on the results of the

Coolant For Maintenance

V×0.014=X

vy-Duty Coolant For Maintenance

Multiplication

Factor

m(V)

Amount of

SCA that is

Required (X)

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.

SEBU8603-01 67

Maintenance Section

Refill Capacities

i04156282

Fluid Recommendations

General Lubricant Information

Because of go
certification of exhaust emissions from the engine,
the lubricant recommendations must be followed.

API_____________________ American Petroleum Institute

•

SAE_______

•

Automotive Engineers Inc.

ACEA_____

•

Constructers European Automobiles.

ECF-3___

•

Licensing

The Engine Oil Licensing and Certification System
by the American Petroleum Institute (API) and
the Asso
Automobilesand (ACRA) is recognized by Perkins.
For detailed information about this system, see the
latest e
Engine oils that bear the API symbol are authorized
by API.

dition of the “API publication No. 1509”.

vernment regulations regarding the

____________________________________

_____________________________

____________________

ciation des Constructers European

Engine Crankcase Fluid

Association des

Society Of

Engine Oil

Commercial Oils

NOTICE

Perkins requ
tion of engine oil. Failure to use the appropriate
specification of engine oil will reduce the life of
your engine
ification of engine oil will also reduce the life of
your aftertreatment system.

Table 16

Classifications for the 1200 Series Industrial Engine

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

•

0. 4 percent maximum sulfur

•

The chemical limits were developed in order
to maintain the expected life of the engine
aftertreatment system. The performance of the
engine aftertreatment system can be adversely
affected if oil that is not specified in table 16 is used.

ire the use of the following specifica-

. Failure to use the appropriate spec-

Oil Specification

Illustration 36

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).

The life of your Aftertreatment system is defined by
the accumulation of ash on the surface of the filter.
Ash is the inert part of the particulate matter. The
system is designed in order to collect this particulate
matter. There is a very small percentage of particulate
matter that is left behind as the soot is burnt. This
matter will eventually block the filter, causing loss
of performance and increased fuel consumption.
Most of the ash comes from the engine oil which is
gradually consumed during normal operation. This
ash is passes through the exhaust. To meet the
designed life of the product, the use of the appropriate
engine oil is essential. The oil specification that is
listed in table 16 has low ash content.

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

affected by the use of biodiesel. Use oil analysis in
order to monitor the condition of the engine oil. Use
oil analysis also in order to determine the oil change
interval that is optimum.

Note: These engine oils are not approved by
Perkins and these engine oils must not be
used:CC, CD, CD-2, CF-4, CG-4, CH-4, and CI-4.

68 SEBU8603-01
Maintenance Section
Refill Capacities

Lubricant Visc

osity Recommendations

for Direct Injection (DI) Diesel Engines

The correct SA
by the minimum ambient temperature during
cold engine start-up, and the maximum ambient
temperature

Refertoillustration37(minimumtemperature)in
order to det
starting a cold engine.

Refer to ill
order to select the oil viscosity for engine operation at
the highest ambient temperature that is anticipated.

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

E viscosity grade of oil is determined

during engine operation.

ermine the required oil viscosity for

ustration 37 (maximum temperature) in

p.

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

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

See the appropriate “Lubricant Viscosities”. Refer

•

totheillustration37inordertofind the correct oil
viscosity

At the specified interval, service the engine. Use

•

new oil and

Perform maintenance at the intervals that are

•

specified
Manual, “Maintenance Interval Schedule”.

Oil anal

Some engines may be equipped with an oil sampling
valve. I
is used to obtain samples of the engine oil. The oil
analysis will complement the preventive maintenance
progra

ysis

f oil analysis is required, the oil sampling valve

m.

ustry standard tests that evaluate

blewiththefinished oils additive

hed oil. This failure could produce sludge

grade for your engine.

install a new oil filter.

in the Operation and Maintenance

Illustration 37

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.

The oil analysis is a diagnostic tool that is used to
determ
rates. Contamination can be identified and measured
by using oil analysis. The oil analysis includes the
follo

•

•

•

ine oil performance and component wear

wing tests:

The Wear Rate Analysis monitors the wear of the

es metals. The amount of wear metal and

engin
type of wear metal that is in the oil is analyzed. The
increase in the rate of engine wear metal in the

s as important as the quantity of engine wear

oil i
metal in the oil.

s are conducted in order to detect

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

Oil Condition Analysis determines the loss of

The
the oils lubricating properties. An infrared analysis
is used to compare the properties of new oil to the

perties of the used oil sample. This analysis

pro
allows technicians to determine the amount of
deterioration of the oil during use. This analysis

so allows technicians to verify the performance

al
of the oil according to the specification during the
entire oil change interval.

SEBU8603-01 69

Maintenance Section

Refill Capacities

Fluid Recommendations

Glossary

•

ISO International Standards Organization

•

ASTM American Society for Testing and Materials

•

HFRR High Fr

•

Lubricity testing of diesel fuels

FAME Fatty

•

CFR Co-ordinating Fuel Research

•

ULSD Ultra Low Sulfur Diesel

•

RME Rape M

•

SME Soy Methyl Ester

•

EPA Environmental Protection Agency of the

•

United States

equency Reciprocating Rig for

Acid Methyl Esters

ethyl Ester

i04224221

Satisfactory e
use of a good quality fuel. The use of a good quality
fuel will give the following results: long engine life
and acceptabl
must meet the minimum requirements that are stated
in the table 17.

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

ngine performance is dependent on the

e exhaust emissions levels. The fuel

NOTICE

es are of the key part Perkins Specifica-

PPM Parts Per Million

•

DPF Dies

•

Genera

Every
information. By use of this document you agree that
Perkins Engines Company Limited is not responsible
for er

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

el Particulate Filter

l Information

NOTICE

attempt is made to provide accurate, up-to-date

rors or omissions.

NOTICE

Diesel Fuel Requirements

rkins is not in a position to continuously evaluate

Pe
and monitor all worldwide distillate diesel fuel
specifications that are published by governments and

chnological societies.

te

The Perkins Specification for Distillate Diesel Fuel

ovides a known reliable baseline in order to judge

pr
the expected performance of distillate diesel fuels
that are derived from conventional sources.

70 SEBU8603-01
Maintenance Section
Refill Capacities

Table 17

Perkins Specification for Distillate Diesel Fuel

Property UNITS Requirements “ASTM”Test “ISO”Test

Aromatics %Volume 35% maximum D1319 “ISO”3837

Ash

Carbon Residue on

%Weight 0.01% maxim

%Weight 0.35% maximum

um D482

D524

10% Bottoms

Cetane Number

(2)

Cloud Point °C

-

40 minimum

The cloud point must

D613/D6890 “ISO”5165

D2500
not exceed the lowest
expected ambient
temperature.

Copper Strip

-

No. 3 maximum D130 “ISO”2160

Corrosion

Density at 15 °C
(59 °F)

Distill

(3)

ation

3

Kg / M

°C 10% at 282 °C

801 minimum and 876
maximum

No equivalent test

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

Flash Point °C legal limit D93 “ISO”2719

Thermal Stability

-

Minimum of 80%

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

Pour Point

°C 6 °C (

42.8 °F) minimum

D97
below ambient
temperature

(1)

Sulfur

Kinematic Viscosity

%mass 0.0

(4)

“MM”2“/S (cSt)” The viscosity of the

015

D5453/D26222 “ISO 20846 ”“ISO 20884”

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

Water and sediment

Water

% weight 0.1% maximum

% weight 0.1% maximum

Sediment % weight 0.05% maximum

Gums and Resins

(5)

mg/100mL

10 mg per 100 mL

D1796

D1744 No equivalent test

D473

D381
maximum

(1)

“ISO”6245

“ISO”4262

“ISO”3015

“ISO 3675 ”“ISO 12185”

”3016

“ISO

“ISO”3734

“ISO”3735

“ISO”6246

(continued)

SEBU8603-01 71

Maintenance Section

Refill Capacities

(Table 17, contd)

Lubricity corrected
wear scar diam
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 standar

maximum den

(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 lubric
High Frequ
supplier.
problems i

eter at

(6)

ds tables, t he equivalent AP I gravity for the minimum density of 801 kg / m

sity of 876 kg / m

ity of a fuel is a concern with ultra low s ulfur fuel. To determine the lubr icity of the fuel, use the “ISO 12156-1 o r ASTM D 6079

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

Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause

n the fuel system.

mm

3

is 30”.

0.52 maximum D6079

“ISO”12156-1

3

(kilograms per cu bic meter) is 45 and for the

Engines that are manufactured by Perkins are
certified w

ith the fuel that is prescribed by the United
States Environmental Protection Agency. Engines
that are manufactured by Perkins are certified
with the f

uel 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 a

nd other appropriate regulatory agencies.

NOTICE
Operating with fuels that do not meet the Perkins rec­ommend

ations can cause the following effects: Start­ing difficulty, reduced fuel filter service life, poor com­bustion, deposits in the fuel injectors, significantly re­duce s

ervice 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 38

g02157153

Illustration 38 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.

72 SEBU8603-01
Maintenance Section
Refill Capacities

Table 18

Acceptable Fuel Specification for the 1200 Series of Engines

Fuel Specification Comments

EN590 European Automotive Diesel Fuel (DERV)

“ASDM D975 G

“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 fu

RADE 1D S15”

els must comply with the specifica tio n in the table for the Perkin s Specification Distillate D iesel Fuel.

“North Amer
PPM sulfur level”

with less than 15 PPM sulfur level”

stated in the section “Lubricity”.

less than 1

ican Light Distillate Diesel fuel with less than 15

0 PPM sulfur level”

(1)

Diesel Fu

el 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 t

o “ISO 5165” for the test method.

Cetane numbers in excess of 45 are normally

ed from current diesel fuel. However, a cetane

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

an have a low cetane value. A minimum cetane

that c
value of 40 is required during average starting
conditions. A fuel with higher cetane number is

mended for operations at high altitudes or in

recom
cold-weather operations.

with a low cetane number can be the root cause

Fuel
of problems during a cold start.

osity

Visc

Viscosity is the property of a liquid of offering

istance to shear or flow. Viscosity decreases

res
with increasing temperature. This decrease in
viscosity follows a logarithmic relationship for normal

sil fuel. The common reference is to kinematic

fos
viscosity. Kinematic viscosity is the quotient of the
dynamic viscosity that is divided by the density. The

termination of kinematic viscosity is normally by

de
readings from gravity flow viscometers at standard
temperatures. Refer to “ISO 3104” for the test

thod.

me

The visco

sity 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

on pump, damage to the fuel injection pump

injecti
can occur. This damage can be excessive scuffing
and seizure. Low viscosity may lead to difficult hot

ting, stalling, and loss of performance. High

restar
viscosity may result in seizure of the pump.

s recommends kinematic viscosities of 1.4 and

Perkin

4.5 mm2/sec that is delivered to the fuel injection
pump. If a fuel with a low viscosity is used, cooling of

el may be required to maintain 1.4 cSt or greater

the fu
viscosity at the fuel injection pump. Fuels w ith a high
viscosity might require fuel heaters in order to lower

scosity to 4.5 cSt at the fuel injection pump.

the vi

Density

Density is the mass of the fuel per unit volume
at a specific temperature. This parameter has a

ct influence on engine performance and a direct

dire
influence on emissions. This influence determines
from a heat output given injected volume of fuel. This

ameter is quoted in the following kg/m

par

3

at 15 °C

(59 °F).

kins recommends a density of 841 kg/m

Per

3

in order
to obtain the correct power output. Lighter fuels are
acceptable but these fuels will not produce the rated

wer.

po

Sulfur

The level of sulfur is governed by emissions
legislations. Regional regulation, national regulations,

r international regulations can require a fuel with

o
aspecific sulfur limit. The sulfur content of the fuel
and the fuel quality must comply with all existing local

egulations for emissions.

r

SEBU8603-01 73

Maintenance Section

Refill Capacities

Perkins 1200 se
designed to operate only with ULSD. By using the
test methods “ASTM D5453, ASTM D2622, or ISO
20846 ISO 2088
must be below 15 PPM (mg/kg) or 0.0015% mass.

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

ries diesel engines have been

4”, the content of sulfur in ULSD fuel

NOTICE

l fuel with higher than 15 PPM sulphur lim-

al.

Lubricity

Lubricity
wear. The fluids lubricity describes the ability of the
fluid to reduce the friction between surfaces that are
under loa
caused by friction. Fuel injection systems rely on the
lubricating properties of the fuel. Until fuel sulfur limits
were man
believed to be a function of fuel viscosity.

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

is the capability of the fuel to prevent pump

d. This ability reduces the damage that is

dated, the fuels lubricity was generally

icity has particular significance to the current

t emissions.

Recommendatio

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

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

Fuel made of 100 percent FAME is generally referred
to as B10

y acids. Biodiesel is a fuel that can be

iodiesel is derived from rapeseed

m soybean oil. Soybean oil or rapeseed oil

ithout esterification, these oils solidify in

engines that are manufactured today.

r biodiesel may include animal tallow, waste

terified.

0 biodiesel or neat biodiesel.

n for Biodiesel

The lubricity of these fuels must not exceed wear scar

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

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

NOTIC
The fuels system has been qualified with fuel hav­ing lubricity up to 0.52 mm (0.0205 inch) wear scar

eter as tested by “ISO 12156-1”. Fuel with higher

diam
wear scar diameter than 0.52 mm (0.0205 inch) will
lead to reduced service life and premature failure of

uel system.

the f

Fuel additives can enhance the lubricity of a fuel.

tact your fuel supplier for those circumstances

Con
when fuel additives are required. Your fuel supplier
can make recommendations for additives to use, and

the proper level of treatment.

for

E

Distillation

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

ydrocarbons can affect the characteristics of

h
combustion.

Biodiesel can be blended with distillate diesel fuel.
The blen
available biodiesel blends are B5, which is 5 percent
biodiesel and 95 percent distillate diesel fuel. B20,
which i
diesel fuel.

Note:

The U.S. distillate diesel fuel specification “ASTM
D975-

European distillate diesel fuel specification EN590:
2010

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

Specification Requirements

The neat biodiesel must conform to the latest
“EN14214 or ASTM D6751” (in the USA). The

odiesel can only be blended in mixture of up to

bi
20% by volume in acceptable mineral diesel fuel
meeting latest edition of “EN590 or ASTM D975 S15”

esignation.

d

ds can be used as fuel. The most commonly

s 20 percent biodiesel and 80 percent distillate

The percentages given are volume-based.

09a” includes up to B5 (5 percent) biodiesel.

includes up B7 (7 percent) biodiesel.

ertified by use of the prescribed Environmental

l. The user of the engine has the responsibility

ropriate regulatory agencies.

74 SEBU8603-01
Maintenance Section
Refill Capacities

In United State
meet the requirements listed in the latest edition of
“ASTM D7467” (B6 to B20) and must be of an API
gravity of 30-

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

In other are
that is BQ-9000 accredited and certified, or that is
accredited and certified by a comparable biodiesel
quality bod
standards is required.

Engine Ser

Aggressive properties of biodiesel fuel may cause
debris in t
properties of biodiesel will clean the fuel tank
and fuel lines. This cleaning of the fuel system
can prema
recommend that after the initial usage of B20
biodiesel blended fuel the fuel filters must be replaced
at 50 hour

Glycerides present in biodiesel fuel will also cause

ers to become blocked more quickly. Therefore

fuel filt
the regular service interval should be reduced to 250
hours.

s Biodiesel blends of B6 to B20 must

45.

ased from the BQ-9000 accredited

as of the world, the use of biodiesel

y to meet similar biodiesel quality

vice Requirements

he fuel tank and fuel lines. The aggressive

turely block of the fuel filters. Perkins

s.

Performance Re

Due to the lower energy content than the standard
distillate fu
of 2 to 4 percent. In addition, over time the power
may deteriorate further due to deposits in the fuel
injectors.

Biodiesel and biodiesel blends are known to cause
an increase
of which are deposits within the fuel injector. These
deposits can cause a loss in power due to restricted
or modified f
issues associated with these deposits.

Note: Perk
effective in cleaning and preventing the formation
of deposits. Perkins Diesel Fuel Conditioner helps
to limit de
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
products
ash can have an impact on the life and performance
of aftertreatment emissions control devices and can
accumul
the need for more frequent ash service intervals and
cause loss of performance

el B20 will cause a power loss in order

posit issues by improving the stability of

upon combustion in the diesel engine. The

ate in DPF. The ash accumulation may cause

lated Issues

in fuel system deposits, most significant

uel injection or cause other functional

ins T400012 Fuel Cleaner is most

When biodiesel fuel is used, crank case oil and
aftertreatment systems may be influenced. This

ce is due to the chemical composition and

influen
characteristics of biodiesel fuel, such as density and
volatility, and to chemical contaminants that can be

nt in this fuel, such as alkali and alkaline metals

prese
(sodium, potassium, calcium, and magnesium).

case oil fuel dilution can be higher when

Crank

•

biodiesel or biodiesel blends are used. This
increased level of fuel dilution when using biodiesel

odiesel blends is related to the typically lower

or bi
volatility of biodiesel. In-cylinder emissions control
strategies utilized in many of the industrial latest

ne designs may lead to a higher level of

engi
biodiesel concentration in the sump. The long-term
effect of biodiesel concentration in crankcase oil is

rently unknown.

cur

Perkins recommend the use of oil analysis in order

•

heck the quality of the engine oil if biodiesel

to c
fuel is used. Ensure that the level of biodiesel in
the fuel is noted when the oil sample is taken.

General Requirements

sel has poor oxidation stability, which can result

Biodie
in long-term problems in the storage of biodiesel.
Biodiesel fuel should be used within 6 months of

acture. Equipment should not be stored with

manuf
the B20 biodiesel blends in the fuel system for longer
than 3 months.

Due to poor oxidation stability and other potential
issues, it is strongly recommended that engines with

ted operational time either not use B20 biodiesel

limi
blends or, while accepting some risk, limit biodiesel
blend to a maximum of B5. Examples of applications

should limit the use of biodiesel are the following:

that
Standby Generator sets and certain emergency
vehicles.

Perkins strongly recommended that seasonally
operated engines have the fuel systems, including

ltanks,flashed with conventional diesel fuel

fue
before prolonged shutdown periods. An example of
an application that should seasonally flush the fuel

stem is a combine harvester.

sy

Microbial contamination and growth can cause

rrosion in the fuel system and premature plugging

co
of the fuel filter. Consult your supplier of fuel for
assistance in selecting appropriate anti-microbial

dditive.

a

SEBU8603-01 75

Maintenance Section

Refill Capacities

Water accelera
growth. When biodiesel is compared to distillate
fuels, water is naturally more likely to exist in the
biodiesel. It
and if necessary, drain the water separator.

Materials su
and zinc accelerate the oxidation process of the
biodiesel fuel. The oxidation process can cause
deposits fo
be used for fuel tanks and fuel lines.

Fuel for Col

The European standard “EN590” contains climate
dependant
options can be applied differently in each country.
There are five classes that are given to arctic climates
and severe

Fuel that complies with “EN590 ” CLASS 4 can be
used at te
Refer to “EN590” for a detailed discretion of the
physical properties of the fuel.

The diesel fuel “ASTM D975 1-D” used in the
United States of America may be used in very cold
tempera

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

tes microbial contamination and

is therefore essential to check frequently

ch as brass, bronze, copper, lead, tin,

rmation therefore these materials must not

d Weather Operation

requirements and a range of options. The

winterclimates.0,1,2,3,and4.

mperatures as low as −44 °C (−47.2 °F).

Perkins fuel cl
form in the fuel system with the use of biodiesel and
biodiesel blends. These deposits can create a loss
of power and en

Once the fuel cleaner has been added to the fuel,
the deposits
after 30 hours of engine operation. For maximum
results, continue to use the fuel cleaner for up to
80 hours. Pe
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
emission c
Perkins fuel system cleaner contains less than 15
ppm of sulfur and is acceptable for use with ULSD
fuel.

eaner will remove deposits that can

gine performance.

within the fuel system are removed

rkins fuel cleaner can be used on an

ontrol catalysts and particulate filters.

Aftermarket Fuel Additives

Supplemental diesel fuel additives are not generally
recommended. This recommendation is due to

ial damage to the fuel system or the engine.

potent
Your fuel supplier or the fuel manufacturer will add
the appropriate supplemental diesel fuel additives.

Perkins recognizes the fact that additives may be
required in some special circumstances. Contact

uel supplier for those circumstances when

your f
fuel additives are required. Your fuel supplier can
recommend the appropriate fuel additive and the

ect level of treatment.

corr

Note: For the best results, your fuel supplier should

t the fuel when additives are required. The treated

trea
fuel must meet the requirements that are stated in
table 17.

Perkins Diesel Fuel System Cleaner

kins T400012 Fuel Cleaner is the only fuel

Per
cleaner that is recommended by Perkins.

biodiesel or biodiesel blends of fuel are to be

If
used, Perkins require the use of Perkins fuel
cleaner. The use of the fuel is in order to remove

posits within the fuel system that is created

de
with the use of biodiesel. For more information on
the use of biodiesel and biodiesel blends refer to

Recommendation for Biodiesel”.

“

76 SEBU8603-01
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

e.

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

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

The 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

N

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.

SEBU8603-01 77

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 39

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.

78 SEBU8603-01
Maintenance Section
Maintenance Interval Schedule

i04220877

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 79

Battery or Battery Cable - Disconnect .................. 80

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

Clean/Replace .................................................... 89

Engine Air C

Inspect/Replace .................................................. 91

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

Fuel Syste

Severe Service Application - Check ................... 105

Daily

Cooling System Coolant Level - Check ................ 85

Driven Equipment - Check .................................... 88

Engine Ai

Engine Air Precleaner - Check/Clean ................... 92

Engine O il Level - Check ...................................... 95

Fuel Sys

Drain ................................................................. 100

Walk-Around Inspection ...................................... 107

Every We

an ...................................................... 88

leaner Element (Single Element) -

m - Prime ............................................. 98

r Cleaner Service Indicator - Inspect ..... 91

tem Primary Filter/Water Separator -

ek

Every 1500 Serv

Engine Crankcase Breather Element - Replace ... 92

Every 2000 Ser

Aftercooler Core - Inspect ..................................... 79

Engine Mount

Starting Motor - Inspect ...................................... 105

Turbocharger - Inspect ........................................ 106

Every 3000 S

Alternator - Inspect ............................................... 79

Alternator

Belt Tensioner - Inspect ........................................ 81

and Fan Belts - Replace ....................... 79

ice Hours

vice Hours

s - Inspect ....................................... 95

ervice Hours

Every 3000 Service Hours or 2 Years

Cooling System Coolant (Commercial Heavy-Duty) -

Change ............................................................... 82

Cooling S

Replace ............................................................... 87

ystem Water Temperature Regulator -

Every 4000 Service Hours

Aftercooler Core - Clean/Test ............................... 79

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 83

Hoses and Clamps - Inspect/Replace ................ 103

Every 5

Fuel Tank Water and Sediment - Drain ............... 102

Every

Belt - Inspect ......................................................... 81

Engin

0 Service Hours or Weekly

500 Service Hours

e Oil and Filter - Change ............................. 96

Every 500 Service Hours or 1 Year

ery Electrolyte Level - Check .......................... 80

Batt
Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 86

ne Air Cleaner Element (Dual Element) -

Engi

Clean/Replace .................................................... 89

Engine Air Cleaner Element (Single Element) -

pect/Replace .................................................. 91

Ins
Fuel System Primary Filter (Water Separator)

Element - Replace .............................................. 98

l System Secondary Filter - Replace ............ 101

Fue

Radiator - Clean .................................................. 104

Every 1000 Service Hours

Water Pump - Inspec t ......................................... 108

SEBU8603-01 79

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.

80 SEBU8603-01
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.

SEBU8603-01 81

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 40

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 41

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

82 SEBU8603-01
Maintenance Section
Cooling System Coolant (Commercial Heavy-Duty) - Change

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

t. Refer to Disassembly and Assembly,

i04007090

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 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.

Illustration 42

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.

Allow the coolant to drain.

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

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

g02177998

SEBU8603-01 83

Maintenance Section

Cooling System Coolant (ELC) - Change

Flush

1. Flush the cool

to remove any debris.

2. Close the drai
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.

3. Fill the co
cooling system filler cap.

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

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

ing system with clean water in order

n cock or install the drain plug in the

NOTICE

oling system with clean water. Install the

run the engine at low idle until the

engine and allow the engine to cool.

ller cap. Open the drain cock or remove

er to drain. Flush the cooling system with

Fill

1. Close

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

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

Illustration 43

Filler cap

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

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

olant level at the maximum mark

g00103639

i04007109

Cooling System Coola nt ( ELC)

-Change

CE

NOTI
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.

l the cooling system with Commercial

2. Fil

Heavy-Duty Coolant. Add Supplemental Coolant
Additive to the coolant. For the correct amount,

fer to the Operation and Maintenance Manual,

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

ecifications. Do not install the cooling system

sp
filler cap.

tart and run the engine at low idle. Increase

3.S

the engine rpm to high idle. Operate the engine
in order to open the engine thermostat. This

rocedure will allow any air in the system to be

p
purged. Decrease the engine speed to low idle.
Stop the engine.

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.

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:

84 SEBU8603-01
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 44

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.

g02177998

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: There are 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.

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.

SEBU8603-01 85

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.

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.

2. Loosen filler cap slowly in order to relieve any

pressure. Remove the fi ller cap.

Illustration 45

Filler cap

g00103639

86 SEBU8603-01
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 46

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.

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

1. 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 47

Cooling system filler cap

0285520

g0

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.

t

SEBU8603-01 87

Maintenance Section

Cooling System Water Temperature Regulator - Replace

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.

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

1. Slowly loosen the cooling system filler cap in

Note: Always discard drained fluids according to

local regulations.

e engine and wait until the cooling system

NOTICE

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

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.

Cooling S y

ng system filler cap and inspect the

, use a suitable pressurizing pump

does not retain the correct pressure,

i04020355

stem Water
Temperature Regulator ­Replace

Replace t
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replaci
the chances for unscheduled downtime. Refer to this
Operation and Maintenance Manual, “Maintenance
Interva
interval.

A water
partially opened position can cause overheating or
overcooling of the engine.

A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overh
head or piston seizure problems.

Awate
position will cause the engine operating temperature
to be too low during partial load operation. Low
engi
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an
of the cylinder liner.

he water temperature regulator before

ng the water temperature regulator reduces

l Schedule” for the proper maintenance

temperature regulator that fails in a

eating could result in cracking of the cylinder

r temperature regulator that fails in the open

ne operating temperatures during partial loads

accelerated wear of the piston rings and wear

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.

88 SEBU8603-01
Maintenance Section
Driven Equipment - Check

i03991933

NOTICE
Failure to rep
on a regularly scheduled basis could cause severe
engine damage.

Perkins engines incorporate a shunt design cooling
system and require operating the engine with a water
temperature

If the water temperature regulator is installed incor­rectly, the
damage. Ensure that the new water temperature reg­ulator is installed in the original position. Ensure that
the water te

Do not use liquid gasket material on the gasket or
cylinder h

lace your water temperature regulator

regulator installed.

engine may overheat, causing cylinder head

mperature regulator vent hole is open.

ead surface.

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 OPERAT

E”.

Refer to two articles in the Disassembly and
Assembly

- Remove and Water Temperature Regulators ­Install” for the replacement procedure of the water
tempera
or your Perkins distributor.

Note: If
replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housin

Manual, “Water Temperature Regulators

ture regulator, or consult your Perkins dealer

only the water temperature regulators are

g.

i02151646

Driven Equipment - Check

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

Inspection

•

Adjustment

•

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

Easy detection of fluid leaks

•

Maximum heat transfer characteristics

•

Ease of maintenance

•

Note: Caution must be used in order to prevent
electrical components from being damaged by
excessive water when the engine is cleaned.
Pressure washers and steam cleaners should not be
directed at any electrical connectors or the junction of
cables into the rear of the connectors. Avoid electrical
components such as the alternator, the starter, and
the ECM. Protect the fuel injection pump from fluids
in order to wash the engine.

Lubrication

•

Other maintenance recommendations

•

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

Aftertreatment

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

SEBU8603-01 89

Maintenance Section

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

i02334355

Engine Air Cleaner Elemen t
(Dual Element

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

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

Servicing the Air Cleaner Elements

Note: The air filter system may not have been

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

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

•

•

•

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

typical air filter system. Refer to the OEM

ir cleaner element becomes plugged, the air

e wear. Refer to the OEM information for the

Check
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
per

the precleaner (if equipped) and the dust

formed regardless of the number of cleanings.

aner elements. Before installation, the air cleaner

the seal of the air cleaner element for damage.

) - Clean/Replace

NOTICE

NOTICE

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

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

When the engine is operating in environments that
are dusty or
more frequent replacement.

Illustration 48

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

1. Remov

cleaner element.

2. The se

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

r cleaner element that is new or cleaned.

ai

cleaner element can be used up

aced at least one time per year. This

he secondary air cleaner element.

dirty, air cleaner elements may require

g00736

e the cover. Remove the primary air

condary air cleaner element should be

431

Dual Element Ai r Cleaners

he dual element air cleaner contains a primary air

T
cleaner element and a secondary air cleaner element.

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.

90 SEBU8603-01
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

Cleaning the Primary Air Cleaner
Elements

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

NOTICE

Do not tap or strike the air cleaner element.

Do not wash the primary air cleaner element.

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

Take extreme care in order to avoid damage to the air
cleaner elements.

Do not use air cleaner elements that have damaged
pleats, gaskets or seals.

Pressurized Ai

Personal injury can result from air pressure.

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

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

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

r

Refer to the OEM information in order to determine
the number of times that the primary air cleaner
element can be cleaned. Do not clean the primary
air filter element more than three times. The primary
air cleaner element must be replaced at least one
time per year.

Cleaning the air filter element will not extend the life
of the air filter element.

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

Two methods may be used in order to clean the
primary air cleaner element:

pressurized air

•

Vacuum cleaning

•

Illustration 49

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

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

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

g00281692

Vacuum Cleaning

Vacuum cleaning is a good method for removing
accumulated dirt from the dirty side (outside) of a
primary air cleaner element. Vacuum cleaning is
especially useful for cleaning primary air cleaner
elements which require daily cleaning because of a
dry, dusty environment.

Cleaning from the clean side (inside) with pressurized
air is recommended prior to vacuum cleaning the
dirty side (outside) of a primary air cleaner element.

SEBU8603-01 91

Maintenance Section

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

Note: Refer to “
Elements”.

Inspecting th

Inspecting the Primary Air Cleaner

e Primary Air Cleaner

Elements

Illustration 50

Inspect
Usea60wattbluelightinadarkroomorinasimilar
facility. Place the blue light in the primary air cleaner
element
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element
for lig
is necessary in order to confirm the result, compare
the primary air cleaner element to a new primary air
cleane

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

the clean, dry primary air cleaner element.

. Rotate the primary air cleaner element.

ht that may show through the filter material. If it

r element that has the same part number.

ars and/or holes in the filter material. Do not

eaner elements.

g00281693

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

A wide variet
with this engine. Consult the OEM information for the
correct procedure to replace the air cleaner.

the air cleaner element with the engine

y of air cleaners may be installed for use

i02335405

Engine Air C lean er Service
Indicator - Inspect

Some engi
service indicator.

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

The service indicator may be mounted on the air
clean

nes may be equipped with a different

ines are equipped with a differential gauge

easured before the air cleaner element and

ssure differential rises. If your engine is

cleaner service indicator.

er element or in a remote location.

i02152042

Engi

ne Air Cleaner
Element (Single Element) ­Inspect/Replace

er to Operation and Maintenance Manual, “Engine

Ref
Air Cleaner Service Indicator-Inspect”.

NOTICE
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.

Illustration 51

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

92 SEBU8603-01
Maintenance Section
Engine Air Precleaner - Check/Clean

Test the Service Indicator

Service indicators are important instruments.

Check for ease of resetting. The service indicator

•

should reset in less than three pushes.

Check the movement of the yellow core when

•

the engine is accelerated to the engine rated
speed. The yellow core should latch at the greatest
vacuum that is attained.

If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be restricted.

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

i02343354

Engine Air Pre cleane r ­Check/Clean

i04151729

Engine Crankcase Breather
Element - Repl

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

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

Care must be taken to ensure that fluids are contained
during p
ing, adjustingand repair of the product. Be prepared to
collect the fluid with suitable containers before open­ing any c
nent containing fluids.

erformance of inspection, maintenance, test-

ompartment or disassembling any compo-

ace

NOTICE

NOTICE

287039

Illustration 52

Typical example

Wing nut

(1)

Cover

(2)

) Body

(3

Remove wing nut (1) and cover (2). Check for an

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

ac
body, if necessary.

fter cleaning the precleaner, install cover (2) and

A
wing nut (1).

g00

Dispos
mandates.

The crankcase breather is a very important
compo
compliant.

•

•

•

•

•

Note: Excessive quantities of oil that enter the
in
the engine speed without control.

eofallfluids according to Local regulations and

nent in order to keep your engine emissions

ter element within the crankcase breather

The fil
must be serviced at the prescribed service interval.

orrect filter element must be installed before

The c
the engine is operated.

nstallation of the filter element is very

The i
important.

quality of the filter element that is installed is

The
very important.

filter element protects the engine from

The
excessive quantities of oil from entering the
induction system. The filter element also protects

e engine aftertreatment system.

th

duction system of the engine can rapidly increase

ote: When the engine is operated in dusty

N

applications, more frequent cleaning is required.

or information on aftermarket products, refer

F
to Operation and Maintenance Manual, “Engine
Description”. Within that section, refer to the title

Aftermarket Products and Perkins Engines”.

“

SEBU8603-01 93

Maintenance Section

Engine Crankcase Breather Element - Replace

The breather el

ement can be serviced from the top
position or the breather element can be serviced from
the bottom position.

Top Service

Illustration 54

Typical exa mple

(B) Alignment position

g02346497

4. Remove the old seal (4) and install a new seal.

Illustration 53

Typical example

(A) Alignment position

g02346496

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 top cap (1) counterclockwise into the

unlocked position. Remove the top cap from the
body of the breather (3).

3. Note the orientation of the filter element (2).

Remove the filter element .

Note: The cut away from section (5) in the top cap
allows access to the seal.

5. Install a new filter element into the breather body
(3). Align position (A) on the filter element to
position (B) on the top cap.

Illustration 55

Typical exa mple

g02346577

6. Install the top cap (1). Rotate the top cap by hand
clockwise until the top cap locks into the locked
position (C) on the breather body.

94 SEBU8603-01
Maintenance Section
Engine Crankcase Breather Element - Replace

7. Remove the cont

Bottom Servic

ainer.

e

Ensure that dirt cannot enter the breather assembly.

Illustration 56

(X) Alignment mark
(Y) Alignment mark

g02346498

1. Ensure that the outside body of the breather
assembly is clean and free from damage. Place
a container under the breather.

2. Remove the tube connection (1). Ensure that
dirt cannot enter the tube connection. Note the
position of the alignment marks (X and Y). Rotate
the bottom cap (2) counterclockwise in order to
release the cap and the filter element (4) from the
breather body (3).

Illustration 57

example

Typical

(A) Alignment postion
(B) Alignment postion

g02346499

3. Note the orientation of the filter element. Remove
the filter element (4) from the bottom cap (2).
Remov

e the seal (5).

Note: The bottom cap has a section that allows

s in order to remove the seal.

acces

4. Install a new seal (5). Install a new filter element

he bottom cap (2).

into t

5. Align position (A) on the filter element to position

n the top cap. Refer to illustration 57.

(B) o

6. Install the assembly of the filter element and the

om cap (2). Rotate the bottom cap by hand

bott
clockwise until the bottom cap locks into the
locked position on the breather body. Ensure

t the alignment marks (X and Y) are correctly

tha
aligned. Refer to illustration 56.

tall tube connection (1). Ensure that the

7. Ins
retaining clips on the tube connection are correctly
engaged. Remove the container.

SEBU8603-01 95

Maintenance Section

Engine Mounts - Inspect

Check the System

Illustration 58

Typical example

Inspect the breather tube (1) for damage. Ensure that
the outlet (2) is clean and free from any obstructions.
Ice can cause obstructions in adverse weather
conditions.

g02346500

i03996001

Engine Oil Leve l - Check

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

ation 59

Illustr

“L” Low

“H” High

skin.

g02173847

i02323089

Engine Mounts - Inspect

Note: The engine mounts may not have been

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

Inspect the engine mounts for deterioration and for
correct bolt torque. Engine vibration can be caused
by the following conditions:

Incorrect mounting of the engine

•

Deterioration of the engine mounts

•

Loose engine mounts

•

Any engine mount that shows deterioration should
be replaced. Refer to the OEM information for the
recommended torques.

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.

lean the oil filler cap. Install the oil filler cap.

C

If an increase in the oil level is noticed, refer to
Troubleshooting, “Oil Contains Fuel”.

96 SEBU8603-01
Maintenance Section
Engine Oil Sample - Obtain

i01907674

Engine Oil Sample - Obta in

The condition of the engine lubricating oil may be
checked at regular intervals as part of a preventive
maintenance
sampling valve as an option. The oil sampling valve
(if equipped) is included in order to regularly sample
the engine l
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 samp
used. The location of the sampling valve allows oil
that is flowing under pressure to be obtained during
normal en

Obtain th

program. Perkins include an oil

ubricating oil. The oil sampling valve is

les are better when a sampling valve is

gine operation.

eSampleandtheAnalysis

The sample can b
quality of the oil, the existence of any coolant in the
oil, the existence of any ferrous metal particles in
the oil, and th
particles in the oil.

Engine Oil a

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

Care must be taken to ensure that fluids are contained
during p
ing, adjustingand repair of the product. Be prepared to
collect the fluid with suitable containers before open­ing any c
nent containing fluids.

erformance of inspection, maintenance, test-

ompartment or disassembling any compo-

e checked for the following: the

e existence of any nonferrous metal

i04021983

nd Filter - Chang e

NOTICE

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

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

•

•

•

•

•

•

Ensure that the container for the sample is clean and
dr
clearly labelled.

To
oil in the crankcase, obtain a warm, well mixed oil
sample.

To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
s

t the skin.

the following information before an oil sample

The d a

Engine model

Engine number

Serv

The number of hours that have accumulated since
the

The amount of oil that has been added since the
las

y. Also ensure that the container for the sample is

amples must be clean.

te of the sample

ice hours on the engine

last oil change

t oil change

ensure that the sample is representative of the

Dispos
mandates.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened
component life.

Do not drain the engine lubricating oil when the
eng
suspended waste particles settle on the bottom of
the oil pan. The waste particles are not removed with
dra
stopped. Drain the oil pan with the oil warm. This
draining method allows the waste particles that are
sus

Failure to follow this recommended procedure will
ca
the engine lubrication system with the new oil.

eofallfluids according to local regulations and

NOTICE

ine is cold. As the engine lubricating oil cools,

iningcoldoil.Draintheoilpanwiththeengine

pended in the oil to be drained properly.

use the waste particles to be recirculated through

Drain the Engine Lubricating Oil

ote: Ensurethatthevesselthatwillbeusedislarge

N

enough to collect the waste oil.

fter the engine has been run at the normal operating

A
temperature, stop the engine. Use one of the
following methods to drain the engine oil pan:

SEBU8603-01 97

Maintenance Section

Engine Oil and Filter - Change

NOTICE
Do not fill the o

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

ents.

4. Install the new oil filter.Spinontheoilfilter until

the O ring co

ntacts the sealing surface (2). Then

rotate the oil filter ¾ of a full turn.

Fill the Oil Pan

Illustration 60

Typical example

If the engine is equipped with a drain valve, turn the

•

g02178063

drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.

If the engine is not equipped with a drain valve,

•

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

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

Replace the Oil F ilter

1. Remove the

oil filler cap. Refer to this
Operation and Maintenance Manual, “Fluid
Recommendations” for more information on
suitable o

ils. Fill the oil pan with the correct
amount of new engine lubricating oil. Refer
to this Operation and Maintenance Manual,
“Refill Ca

pacities” for more information on refill

capacities.

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.

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

1. Place a suitable container below the oil filter

assembly. Remove the oil filterwithasuitabletool.

2. Clean sealing surface of the oil filter base (2).

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

new oil filter.

Illustration 61

g02173847

4. Remove the engine oil level gauge in order to
check the oil level. Maintain the oil level between
the“L”and“H”marksontheengineoillevel
gauge. Do not fill the crankcase above the “H”
mark.

98 SEBU8603-01
Maintenance Section
Fuel System - Prime

i03906114

Fuel System - Prime

Note: Refer to
and Adjusting, “Cleanlines s of Fuel System
Components” for detailed information on the
standards of
during ALL work on the fuel system.

Ensure that
by authorized personnel that have had the correct
training.

Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes b

If air enters the fuel system, the air must be purged
from the
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 e

•

The fuel filter has been replaced.

•

fuel system before the engine can be

Systems Operation, Testing,

cleanliness that must be observed

all adjustments and repairs are performed

NOTICE

efore cranking the engine again.

xists in the low-pressure fuel system.

Note: Operatin
ensure that the fuel system is free of air. DO NOT

loosen the high-pressure fuel lines in order to
purge air from
not required.

After the eng
10 minutes in order to allow the fuel pressure to
be purged from the high-pressure fuel lines before
any service
fuel lines. If necessary, perform minor adjustments.
Repair any leaks from the low-pressure fuel system
and from the
Replace any high-pressure fuel line that has leaked.
Refer to Disassembly and Assembly Manual, “Fuel
Injection

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

If the engine will not start, refer to Troubleshooting,
“Engine Cranks but will not Start”.

g the engine for this period will help

the fuel system. This procedure is

ine has stopped, you must wait for

or repair is performed on the engine

cooling, lubrication, or air systems.

Lines - Install”.

inspection procedure in order to avoid

i04224203

Fuel System Primary Filter
(Water Separator) Element ­Replace

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

1. Ensure that the fuel system is in working order.
Check that the fuel supply valve (if equipped) is in

ON” position.

the “

2. Turn the keyswitch to the “RUN” position.

3. The keyswitch will allow the electric priming pump

to operate. Operate the electric priming pump.

ECM will stop the pump after 2 minutes.

The

4. Turnthekeyswitchtothe“OFF”position.Thefuel

tem should now be primed and the engine

sys
should be able to start.

erate the engine starter and crank the engine.

5. Op
After the engine has started, operate the engine at
low idle for a minimum of 5 minutes. Ensure that

efuelsystemisfreefromleaks.

th

eaked or spilled onto hot surfaces or elec-

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

ging fuel filters or water separator elements.

chan
Cleanupfuelspillsimmediately.

: Refer to Systems Operation, Testing,

Note
and Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the

ndards of cleanliness that m ust be observed

sta
during ALL work on the fuel system.

NOTICE

sure that the engine is stopped before any servicing

En
or repair is performed.

Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFF

position before performing this maintenance.

SEBU8603-01 99

Maintenance Section

Fuel System Primary Filter (Water Separator) Element - Replace

2. Place a suitabl

e container under the water
separator in order to catch any fuel that might spill.
Clean up any spilled fuel. Clean the outside body
of the filter as

sembly.

3. Make a temporary Mark (A) across the filter before
the assembly

is removed.

Illustration 62

Typical example

g02148376

4. Install a suitable tube onto drain (3). Open
the drain valve (2). Rotate the drain valve
counterclockwise. Two full turns are required.
Loosen vent screw (1).

Note: Two complete rotations of the valve will release
the valve from the filter element.

5. Allow the fuel to drain into the container. Remove
thetubeandinstallthevalveintothefilter element.
Engage the threads of the valve into the filter
element. Do not secure the valve.

6. Tighten the vent screw (1) securely . Remove the
wiring harness from connection (4).

7. Remove the filter bowl (6). Rotate the filter
assembly counterclockwise in order to remove
the filter assembly. Use a suitable tool in order to
remove the filter assembly.

Illustration 63

example

Typical

g02148402

8. Rotate the filter element counterclockwise and
remove

the filter element (5). Clean the filter bowl.

100 SEBU8603-01
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

Install the Element

i03980098

Fuel System Primary
Filter/Water

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

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

The water separator can be under suction during nor­mal engi
tightened securely to help prevent air from entering
the fuel system.

ne operation. Ensure that the drain valve is

Separator - Drain

NOTICE

NOTICE

Illustration 64

Typical example

1. Locate
threads (9). Spin on the element. Do not tighten.

2. Lubri
Do NOT fill the bowl with fuel before the assembly
is installed.

3. Do not use a tool in order to install the filter
assembly. Tighten the filter bowl (6) by hand.
Inst
temporary marks (A).

4. Tigh
container and dispose of the fuel in a safe place.

5. The s
thesametimeastheprimaryfilter element. Refer
to the Operation and Maintenance Manual , “Fuel
Sys

In-

the thread in the filter element (8) onto the

cate the O ring seal (7) with clean engine oil.

all the filter bowl (6) and align with your

ten the valve (2) securely. Remove the

econdary filter element must be replaced at

tem Filter - Replace”.

line Strainer

g021484

41

1. Place a suitable container under the water
separator in order to catch any fluid that might

Cleanupanyspilledfluid.

spill.

2. Ensure that the outer body of the filter assembly is

and free from dirt.

clean

The fuel system has an in-line strainer installed before

e electric priming pump. Perkins recommended

th
that the in-line strainer be replaced when required.

e location of the in-line strainer will depend on the

Th
application.

Illustration 65

Typical exa mple

g02148370