Perkins Engine 2506D-E15TA Service Manual

Operation and
Maintenance
Manual

M0080243-01 (en-us)

August 2017

2506D-E15TA Industrial Engine

PK5 (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.

M0080243-01 3

Table of Contents

Table of Contents

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

Safety Section

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

General Hazard Information.............................. 7

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

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

Crushing Prevention and Cutting Prevention.. 12

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

Before Starting Engine .................................... 13

Engine Starting................................................ 13

Engine Stopping .............................................. 14

Refill Capacities............................................... 40

Maintenance Recommendations .................... 56

Maintenance Interval Schedule....................... 59

Index Section

Index................................................................ 86

Electrical System............................................. 14

Engine Electronics........................................... 14

Product Information Section

General Information ........................................ 16

Product Identification Information ................... 20

Operation Section

Lifting and Storage .......................................... 21

Features and Controls..................................... 25

Engine Diagnostics ......................................... 29

Engine Starting................................................ 31

Engine Operation ............................................ 35

Cold Weather Operation ................................. 37

Engine Stopping .............................................. 39

Maintenance Section

4 M0080243-01

Foreword

Foreword

Literature Information

This manual contains safety, operation instructions,
lubrication and maintenance information. This

manual should be stored in or near the engine area in
a literature holder or literature storage area. Read,
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 consistency.

Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Perkins dealer or your Perkins
distributor for the latest available information.

Safety

This safety section lists basic safety precautions. In
addition, this section identifies hazardous, warning
situations. Read and understand the basic

precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.

Operation

Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.

The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.

Maintenance

The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are

referenced to detailed instructions that follow.

Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
wet or freezing cold operating conditions, more
frequent lubrication and maintenance than is
specified in the Maintenance Interval Schedule may
be necessary.

The maintenance schedule items are organized for a
preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of the
original requirement. We recommend that the
maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be

maintained as part of the engine's permanent record.

Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.

Overhaul

Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.

Major repairs should only be carried out by Perkins
authorized personnel. Your Perkins dealer or your
Perkins distributor offers a variety of options
regarding overhaul programs. If you experience a
major engine failure, there are also numerous after
failure overhaul options available. Consult with 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,

birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.

M0080243-01

Safety Section

i06918984

Safety Messages

SMCS Code: 1000; 7405

There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages are reviewed in this section.
Become familiar with all safety messages.

Ensure that all the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and

soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off the
engine.

5

Safety Section

Safety Messages

Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Perkins
distributor can provide new safety messages.

2506D-E15TA Safety Label Positions

Illustration 1 g06167616

Typical example

6 M0080243-01

Safety Section
Safety Messages

Illustration 2 g06167638

Typical example

Universal Warning (1)

Illustration 3 g01370904

One safety message is on the left side of the engine.
One safety message is on the right side of the
engine.

M0080243-01

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

heed the warnings could result in serious injury
or death.

i06214236

7

Safety Section

General Hazard Information

• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers
are secured in place on the engine.

• Never put maintenance fluids into glass
containers. Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

General Hazard Information

SMCS Code: 1000; 4450; 7405

Illustration 4 g00104545

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 appropriate,
disconnect the starting controls.

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

• The engine is stopped. Ensure that the engine
cannot be started.

• The protective locks or the controls are in the
applied position.

• Engage the secondary brakes or parking brakes.

• Block the vehicle or restrain the vehicle before
maintenance or repairs are performed.

• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks. If
equipped, allow the diesel exhaust fluid to be
purged before disconnecting the battery.

• If equipped, disconnect the connectors for the unit
injectors that are located on the valve cover base.
This action will help prevent personal injury from
the high voltage to the unit injectors. Do not come
in contact with the unit injector terminals while the
engine is operating.

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.

• Vent the engine exhaust to the outside when the
engine is operated in an enclosed area.

• If the engine is not running, do not release the
secondary brake or the parking brake systems
unless the vehicle is blocked or unless the vehicle
is restrained.

• Wear a hard hat, protective glasses, and other
protective 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.

• Do not attempt any repairs or any adjustments to
the engine while the engine is operating.

• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.

• For initial start-up of a new engine or for starting
an engine that has been serviced, make
provisions to stop the engine if an overspeed
occurs. The stopping of the engine may be
accomplished by shutting off the fuel supply and/
or the air supply to the engine. Ensure that only
the fuel supply line is shut off. Ensure that the fuel
return line is open.

• Start the engine from the operators station (cab).
Never short across the starting motor terminals or
the batteries. This action could bypass the engine
neutral start system and/or the electrical system
could be damaged.

8 M0080243-01

Safety Section
General Hazard Information

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

Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last
two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.

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. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.

Pressurized Air and Water

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

When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
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
water pressure for cleaning purposes must be below
275 kPa (40 psi).

Illustration 5 g00702020

• 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.

• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers
are secured in place on the engine.

• Never put maintenance fluids into glass
containers. Glass containers can break.

• Use all cleaning solutions with care.

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved
correctly.

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

• Report all necessary repairs.

M0080243-01 9

Safety Section

General Hazard Information

Avoid static electricity risk when fueling. Ultra­low sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formula­tions with a higher sulfur contents. Avoid death
or serious injury from fire or explosion. Consult
with your fuel or fuel system supplier to ensure
the delivery system is in compliance with fueling
standards for proper grounding and bonding
practices.

Inhalation

Illustration 6 g00687600

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.

Containing Fluid Spillage

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.

Static Electricity Hazard when
Fueling with Ultra-low Sulfur Diesel
Fuel

The removal of sulfur and other compounds in ultra­low sulfur diesel fuel (ULSD fuel) decreases the
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.

Illustration 7 g00702022

Exhaust

Use caution. Exhaust fumes can be hazardous to
health. If you operate the equipment in an enclosed

area, adequate ventilation is necessary.

Asbestos Information

Perkins equipment and replacement parts that are
shipped from Perkins engine company limited are
asbestos free. Perkins recommends the use of only
genuine Perkins replacement parts. Use the following
guidelines when you handle any 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 fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.

If dust that may contain asbestos is present, there
are several guidelines that should be followed:

• Never use compressed air for cleaning.

10 M0080243-01

Safety Section
Burn Prevention

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.

• A vacuum cleaner that is equipped with a high
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
Occupational Safety and Health Administration
(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.

Dispose of Waste Properly

Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.

i06214247

Burn Prevention

SMCS Code: 1000; 4450; 7405

Coolant

When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.

Allow cooling system components to cool before the
cooling system is drained.

Check that the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.

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

Illustration 8 g00706404

Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.

Oils

Skin may be irritated following repeated or prolonged
exposure to mineral and synthetic base oils. Refer to
your suppliers Material Safety Data Sheets for
detailed information. Hot oil and lubricating
components can cause personal injury. Do not allow
hot oil to contact the skin. Appropriate personal
protective equipment should be used.

Diesel Fuel

Diesel may be irritating to the eyes, respiratory
system, and skin. Prolonged exposure to diesel may
cause various skin conditions. Appropriate personal
protective equipment should be used. Refer to
supplier Material safety Data sheets for detailed
information.

Batteries

The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.

Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.

M0080243-01 11

Safety Section

Fire Prevention and Explosion Prevention

Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.

i06214251

Fire Prevention and Explosion
Prevention

SMCS Code: 1000; 4450; 7405

Illustration 9 g00704000

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.

Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line, a
tube, or a seal failure. Exhaust shields must be

installed correctly.

Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior to
welding or flame cutting.

Wiring must be kept in good condition. Ensure that all
electrical wires are correctly installed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.

Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
or sparking.

Ensure that the engine is stopped. Inspect all lines
and hoses for wear or for deterioration. Ensure that

the hoses are correctly routed. The lines and hoses
must have adequate support and secure clamps.

Oil filters and fuel filters must be installed correctly.
The filter housings must be tightened to the correct
torque. Refer to the Disassembly and Assembly
manual for more information.

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.

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.

Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for

storing flammable materials.

Do not expose the engine to any flame.

Illustration 10 g00704059

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

12 M0080243-01

Safety Section
Crushing Prevention and Cutting Prevention

Avoid static electricity risk when fueling. Ultra-low
Sulfur Diesel fuel (ULSD fuel) poses a greater static
ignition hazard than earlier diesel formulations with a
higher sulfur content. Avoid death or serious injury
from fire or explosion. Consult your fuel or fuel
system supplier to ensure that the delivery system is
in compliance with fueling standards for proper
grounding and bonding practices.

Fire Extinguisher

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

Ether

Ether is flammable and poisonous.

Do not smoke while you are replacing an ether
cylinder or while you are using an ether spray.

Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49° C
(120° F). Keep ether cylinders away from open
flames or sparks.

Lines, Tubes, and Hoses

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

Leaks can cause fires. Consult your Perkins dealer or
your Perkins distributor for replacement parts.

Illustration 11 g00704135

Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.

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

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

Do not charge a frozen battery. A frozen battery may
cause an explosion.

The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.

Replace the parts if any of the following conditions
are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation,
correct installation will help to prevent vibration,
rubbing against other parts, and excessive heat.

i06214255

Crushing Prevention and
Cutting Prevention

SMCS Code: 1000; 4450; 7405

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

M0080243-01 13

Safety Section

Mounting and Dismounting

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

Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
performed. After the maintenance is performed,
reinstall the guards.

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

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

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

i06214256

Mounting and Dismounting

SMCS Code: 1000; 4450; 7405

Do not climb on the engine or the radiator. The
engine and radiator 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.

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

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

Do not start an engine when the governor linkage is
disconnected.

Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are

provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.

i06214258

Engine Starting

SMCS Code: 1000

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

i06214257

Before Starting Engine

SMCS Code: 1000

NOTICE

For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.

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

to the outside.

Inspect the engine for potential hazards.

Do not start the engine or move any of the controls if
there is a “DO NOT OPERATE” warning tag or similar
warning tag attached to the start switch or the
controls.

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

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

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

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

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

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

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

14 M0080243-01

Safety Section
Engine Stopping

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

i01462046

Engine Stopping

SMCS Code: 1000

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

Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.

Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to the
engine and/or shutting off the air supply to the
engine.

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

Grounding Practices

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

Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.

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

To ensure that the engine and the engine electrical
systems function properly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a starting
motor ground, a starting motor ground to the frame,
or a direct engine ground to the frame.

All grounds should be tight and free of corrosion. The
engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.

i06214264

Engine Electronics

SMCS Code: 1000; 1900

i06214263

Electrical System

SMCS Code: 1000; 1400

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

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

Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
the Operation and Maintenance Manual, “Engine
Starting” for specific starting instructions.

Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.

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

The following actions are available for engine
monitoring control: WARNING, DERATE and
SHUTDOWN. These engine monitoring modes can
limit engine speed and/or the engine power.

Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring
functions. The following parameters can be
monitored as a part of the Engine Monitoring System:

• Operating Altitude

• Engine Coolant Level

• Engine Coolant Temperature

• Engine Oil Pressure

M0080243-01 15

Safety Section

Engine Electronics

• Engine Speed

• Fuel Temperature

• Intake Manifold Air Temperature

• System Voltage

The Engine Monitoring package can vary for different
engine models and different engine applications.
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 unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting
manual for more information.

16 M0080243-01

Product Information Section
General Information

Product Information
Section

General Information

i06919047

Model View Illustrations

SMCS Code: 1000

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 12 g06167718

Typical example

(1) Refrigerant compressor
(2) Oil filler cap
(3) Oil gauge (Dipstick)
(4) Air intake

(5) Breather hose
(6) Secondary fuel filters
(7) Electronic control module
(8) Starting motor

(9) Breather outlet
(10) Oil drain plug
(11) Fuel transfer pump
(12) Alternator

M0080243-01 17

Product Information Section

Model View Illustrations

Illustration 13 g06167725

Typical example

(13) Turbocharger
(14) Front lifting eye
(15) Coolant outlet
(16) Coolant pump

(17) Coolant intake
(18) Connections to remote oil filter
(19) Oil drain valve
(20) Oil cooler

(21) Remote oil filter
(22) Flywheel
(23) Flywheel housing
(24) Rear lifting eye

18 M0080243-01

Product Information Section
Product Description

Illustration 14 g06167762

Typical example

(25) Drive belt idler
(26) Drive belt idler

(27) Auto Tensioner for drive belt
(28) Drive belt idler

i06925231

(29) Damper
(30) Drive belt

Product Description

SMCS Code: 1000; 4450; 4491

The Perkins 2506D-E15TA Industrial Engine has the
following characteristics:

• Four-stroke cycle

• Mechanically actuated, electronically controlled
fuel injection system

• Turbocharged

• Air to air charged cooled

Engine Specifications

Note: The front end of the engine is opposite the

flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.

Illustration 15 g01387009

Cylinder and valve location

(A) Exhaust valve
(B) Inlet valve

Table 1

Engine Specifications

Engine

2506D

(continued)

M0080243-01 19

Product Information Section

Product Description

(Table 1, contd)

Arrangement and Cylinders In-Line 6 cylinder

Bore 137.2 mm (5.4 inch)

Stroke 171.5 mm (6.8 inch)

Aspiration

Displacement 15.2 L (928 cubic inch)

Firing Order

Rotation (flywheel end)

(1)

Air-to-air aftercooled

Counterclockwise

(1)

ATAAC

1-5-3-6-2-4

Electronic Engine Features

The engine is designed for electronic controls. The
integral on board computer controls the operation of
the engine. Current 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 speed governor

• Automatic air/fuel ratio control

• Torque rise shaping

• Injection timing control

• System diagnostics

Most of the diagnostic codes are logged and stored in
the ECM. For additional information, refer to

theOperation and Maintenance Manual, Engine
Diagnostictopic (Operation Section).

Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants, and

lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.

Expected engine life is predicted by the average
power that is demanded. The average power that is
demanded is based on fuel consumption of the
engine over a time. Reduced hours of operation at
full throttle and/or operating at reduced throttle
settings result in a lower average power demand.
Reduced hours of operation will increase the length
of operating time before an engine overhaul is
required. For more information, refer to the Operation
and Maintenance Manual, “Overhaul Considerations”

topic.

Aftermarket 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 manufacturers are used on Perkins
products, the Perkins warranty is not affected simply
because of such use.

Extra Features

The following extra features provide increased
engine fuel economy and serviceability:

• Cold starting capability

• Tampering detection

• Diagnostics

Engine Diagnostics

The engine has built-in diagnostics to ensure that all
the components are functioning properly. Under
certain conditions, the engine horsepower and the
vehicle speed may be limited. An electronic service
tool may be used to display the diagnostic code.

There are two categories of codes: diagnostic code
and event code. These two categories of codes may
be in two different states: active and logged.

However, failures that result from the installation
or use of other manufacturers devices,
accessories, or consumables are NOT Perkins
defects. Therefore, the defects are NOT covered
under the Perkins warranty.

20 M0080243-01

Product Information Section
Product Identification Information

Product Identification
Information

i06925245

Plate Locations and Film
Locations

SMCS Code: 1000; 4450

Illustration 16 g06169809

Typical example

The engine serial number plate is on the right side of
the engine block.

Illustration 17 g01403841

Serial number plate

The following information is stamped on the serial
number plate: engine serial number, engine model,
and arrangement number.

i06925248

Emissions Certification Film

SMCS Code: 1000; 7405

The emissions label is on the oil cooler.

M0080243-01 21

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i06925250

Product Lifting

SMCS Code: 7000; 7002

Illustration 18 g00103219

Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Re­member that the capacity of an eyebolt is less as the
angle between the supporting members and the ob­ject becomes less than 90 degrees.

When it is necessary to remove a component at an
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
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.

Some removals require lifting the fixtures to obtain
proper balance and safety.

To remove the engine ONLY, use the lifting eyes that
are on the engine.

Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting
eyes and/or the engine make the lifting eyes and the
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Perkins distributor for information
regarding fixtures for proper engine lifting.

NOTICE

22 M0080243-01

Operation Section
Product Storage

Engine Lifting

Illustration 19 g06044076

Typical example

(1) Engine lifting eyes

Use an appropriate spreader set so that lifting chains
are perpendicular to the engine.

i06216666

Product Storage

SMCS Code: 7002

Your Perkins distributor can assist in preparing the
engine for extended storage periods.

An engine can be stored for up to 6 months provided
all the recommendation are adhered to.

Engine

1. Clean the engine of any dirt, rust, grease, and oil.

Inspect the exterior. Paint areas that contain paint
damage with a good quality paint.

2. Remove dirt from the air cleaners. Check all seals,
gaskets, and the filter element for damage.

3. Apply lubricant to all points in this Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.

4. Drain the crankcase oil. Replace the crankcase oil
and change the oil filters. For the proper
procedure, refer to this Operation and
Maintenance Manual.

5. Add VCI oil to the crankcase oil. The volume of
VCI oil in the crankcase oil should be 3 to 4
percent.

Note: If the engine crankcase is full, drain enough
engine oil so the mixture can be added.

6. Remove the air filter elements. Turn the engine at
cranking speed with the throttle control in FUEL
OFF position. Use a sprayer to add a mixture of 50
percent VCI oil and 50 percent engine oil into the
air inlet or turbocharger inlet.

M0080243-01 23

Operation Section

Product Storage

Note: The mixture can be added to the inlet by
removing the plug on the air inlet elbow on the left
side of the engine. The minimum application rate for
the VCI oil mixture is 5.5 mL per L
(3 oz per 1000 cu in) of engine displacement.

7. Use a sprayer to apply a mixture of 50 percent VCI
oil and 50 percent crankcase oil into the exhaust
openings. The minimum application rate for the oil
mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement. Seal the exhaust pipe and
seal any drain holes in the muffler.

8. Empty and reinstall the spin-on fuel filter element
in order to remove any dirt and water. Drain any
sleeve metering fuel pump.

Clean the primary fuel filter. Fill with calibration
fluid or kerosene. Install the primary fuel filter and
operate the priming pump. This procedure will
send clean oil to the secondary filter and the
engine.

Open the fuel tank drain valve in order to drain any
water and dirt from the fuel tank. Apply a spray of
calibration fluid or kerosene at the rate of

30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
capacity in order to prevent rust in the fuel tank.
Add 0.15 mL per L (.02 oz per 1 gal US) of
commercial biocide such as Biobor JF to the fuel.

Apply a small amount of oil to the threads on the
fuel tank filler neck and install the cap. Seal all
openings to the tank in order to prevent
evaporation of the fuel and as a preservative.

9. Remove the fuel injectors. Apply 30 mL (1 oz) of
the mixture of oils (50 percent VCI oil and 50
percent engine oil) into each cylinder.

Use a bar or a turning tool in order to turn over the
engine slowly. This procedure puts the oil on the
cylinder walls. Install all fuel injectors and tighten
to the correct torque. Refer to Disassembly and
Assembly Manual for more information.

10. Spray a thin amount of a mixture of 50 percent
VCI oil and 50 percent engine oil onto the following
components: flywheel, ring gear teeth and starter
pinion. Install the covers in order to prevent
evaporation of the vapors from the VCI oil.

11. Apply a heavy amount of Multipurpose Grease to
all outside parts that move, such as rod threads,
ball joints, linkage.

Note: Install all covers. Ensure that tape has been
installed over all openings, air inlets, exhaust
openings, the flywheel housing, the crankcase
breathers, the dipstick tubes.

Ensure that all covers are airtight and
weatherproof. Use a waterproof weather resistant
tape such as Kendall No. 231 or an equivalent. Do
not use duct tape. Duct tape will only seal for a
short time.

12. Under most conditions, removing the batteries is
the best procedure. As an alternative, place the
batteries in storage. As needed, periodically
charge the batteries while the batteries are in
storage.

If the batteries are not removed, wash the tops of
the batteries until the tops are clean. Apply an
electrical charge to the batteries in order to obtain
a specific gravity of 1.225.

Disconnect the battery terminals. Place a plastic
cover over the batteries.

13. Remove the drive belts from the engine

14. Place a waterproof cover over the engine. Ensure

that the engine cover is secure. The cover should
be loose enough to allow air to circulate around
the engine in order to prevent damage from
condensation.

15. Attach a tag with the storage date to the engine.

16. Remove the waterproof cover at 2 month or 3

month intervals in order to check the engine for
corrosion. If the engine has signs of corrosion,
repeat the protection procedure.

Coolant System

Completely fill the cooling system before storage.

Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for more information about

coolants.

Remove Engine from Storage

1. Remove all outside protective covers.

2. Change the oil and filters.

3. Check the condition of the fan and alternator belts.

Replace the belts, if necessary. Refer to this
Operation and Maintenance Manual, “Belts ­Inspect/Adjust/Replace” for the correct procedure.

4. Replace the fuel filter elements.

5. Remove the plastic covers from the air cleaner

elements.

6. Use a bar or a turning tool in order to turn the
engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.

24 M0080243-01

Operation Section
Product Storage

7. Before starting the engine, remove the valve cover
or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism in
order to prevent damage to the mechanism.

Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.

Prime the engine with clean diesel fuel before
starting.

11. Ensure that the cooling system is clean. Ensure
that the system is full. Ensure that the system has
the correct amount of supplemental cooling
system conditioner.

12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.

Illustration 20 g03862009

Oil priming point

(1) Plug

8. If an engine is stored for more than 1 year, Perkins
recommends prelubrication of the engine in order
to avoid dry starting. Use a suitable pump in order
to put engine oil into the engine oil system.

The pump will need to create a minimum pressure
within the engine of 0.25 bar (3.6 psi). This
pressure is needed for 15 seconds in order to
lubricate the internal surfaces.

Remove the plug shown in illustration 20 in order
to connect to the engine oil system. The
connection required is 9/16" x 18 tpi. Ensure that
the correct oil specification is used, refer to this
Operation and Maintenance Manual, “Fluid
Recommendations” for more information. After the

engine internal surfaces have been lubricated,
remove connector and install plug (1). Tighten plug
to a torque of 30 N·m (265 lb in). Perkins
recommends that the procedure must be
performed in a minimum ambient temperature of
10° C (50° F).

9. Check the condition of all rubber hoses. Replace
any worn hoses. Replace any damaged hoses.

10. Before start-up, test the cooling system for a 3
percent to a 6 percent concentration of coolant
conditioner. Add liquid coolant conditioner or a
coolant conditioner element, if equipped.

M0080243-01 25

Operation Section

Features and Controls

Features and Controls

i06216788

Monitoring System

SMCS Code: 1900; 7400; 7450; 7451

The monitoring system is designed to alert the
operator to an immediate problem.

The engine has protection in three stages:

• Warning

• Action Alert

• Shutdown

The engine protection may be overridden by the
critical condition mode.

The Electronic Control Module (ECM) monitors the
following parameters:

• Engine Temperatures

• Engine Pressures

• Engine Speed

If the engine is in the Warning condition, then the
event will be logged in the memory of the ECM. An
event code will be transmitted over the Perkins Data

link and the hard wired Warning output will be
energized. If the engine is in the Warning condition,
the event code and output will remain while the
condition exists. The electronic service tool is used to

remove the event code from the memory of the ECM.
The trip point for the Warning alarm will be set to a
factory default in production. The electronic service
tool may be used to alter the trip point for a Warning
within predefined limits.

Action Alert

The Action Alert informs the OEM that the engine is
approaching a critical condition. The engine should
be stopped in a controlled manner. Further running of
the engine may result in an immediate shutdown.

If the engine is in the Action Alert condition, the event
will be logged in the memory of the ECM. An event
code will be transmitted over the Perkins Data link

and the hard wired Action Alert will be energized. If
the engine is in the Action Alert condition, the event
code and output will remain while the condition
exists. The event code cannot be cleared from the

memory of the ECM without using a factory
password.

If the parameters exceed a trip point for a period that
is longer than the delay period, the ECM logs an
event code. The indicator switches to the ON

position.

The following parameters are monitored for event
codes:

• Lubricating Oil Pressure

• Coolant Temperature

• Overspeed

• Intake Manifold Temperature

• Intake Manifold Pressure

• Fuel Temperature

The temperature protection is disabled for a period
when the engine is cranking in order to compensate
for heat soak solutions.

The ECM has dedicated alarm outputs for each of the
three stages of protection. There are also dedicated
alarm outputs for oil pressure, coolant temperature,
and overspeed events which are energized at any
stage of protection.

Shutdown

If the engine reaches the Shutdown condition, one of
the following events has occurred: low lubricating oil
pressure, high coolant temperature, or overspeed.
The event will be logged in the memory of the ECM.
The engine will be shut down. An event code will be
transmitted over the Perkins Data link and the hard

wired Shutdown output will be energized. The
Shutdown condition will latch until the ECM is reset.

The event code for the shutdown cannot be cleared
from the memory of the ECM without using a factory

password.

Critical Protection Override

In an application that is critical for safety, the
protection system can be overridden in order to
ensure continued engine operation during fault
conditions.

Critical Protection Override will be set by a switch
input from the OEM. For example, switch to battery +
in order to disable a critical override. Critical

Protection Override input can be enabled in the
electronic service tool by use of a factory password.

Warning Alarm

The Warning alarm informs the user that the engine
is approaching a critical condition.

26 M0080243-01

Operation Section
Sensors and Electrical Components

When the Critical Protection Override feature is
active, the ECM will continue to run the engine in all

shutdown conditions except for Overspeed
shutdown. If the shutdown is overridden, an event

code is generated. The ECM will log the event code.
The ECM will energize the following: Warning, Action
Alert, Shutdown, oil pressure, coolant temperature
and overspeed outputs as normal. The warranty of
the engine will be invalidated if the engine is
operated in the following conditions: active event
code and Critical Protection Override mode.

Standard Warning Outputs

The ECM provides individual outputs in order to drive
warning lamps or relays to indicate each of the
following fault conditions:

• Diagnostic Fault

• Oil Pressure

• Coolant Temperature

• Overspeed

• Action Alert

• Warning

• Shutdown

If the ECM detects a coolant temperature warning,
the warning output will be energized. If the ECM
detects a warning for low oil pressure, the warning
output will be energized.

If the Action Alert alarms are enabled and the ECM
detects a coolant temperature condition, the output

on the Action Alert will be energized.

If the engine shuts down on low oil pressure, the
output on the shutdown will be energized. If the
engine shuts down on coolant temperature, or the
engine shuts down on overspeed, the shutdown
output will be energized.

Shutdown Reset

The cause of an engine shutdown must be
investigated. Corrective action must be taken before
the system is reset in order to operate the engine.

Note: The ECM cannot be reset by using the Reset
input until the engine has stopped.

Diagnostic

If there is a fault with an engine protection sensor on
the engine, the engine activates a diagnostic code.
The engine communicates the diagnostic code to the
operator via the Diagnostic output. The diagnostic
code provides an indication to the operator of a fault
with the engine protection system. Running of the
engine for a prolonged period in this condition may
result in engine failure. The output is normally used to
drive lamps or relays.

The following sensors are monitored in order to
determine if the sensors are out of the normal range,
an open circuit, or a short circuit:

• Atmosphere Pressure

• Lubricating Oil Pressure

• Inlet Manifold Pressure

• Inlet Manifold Temperature

• Fuel Temperature

• Coolant Temperature

• Engine Speed

• Desired Speed Input

The Diagnostic output differs from the Warning and
Shutdown outputs. The Warning and Shutdown
outputs refer to the operation of the engine. The
Diagnostic output refers to the condition of the
electronic system and software system.

A diagnostic fault may develop on the lubricating oil
pressure or coolant temperature sensors. For
example, if a Shutdown protection sensor has a fault,
the result will be an engine shutdown, unless the
system is in critical protection override. If a diagnostic
fault occurs, with one of the engine speed sensors
while the engine is running. The engine continues to
run by using the other timing sensor for reference.

i06925252

After an engine shutdown, operate the reset input of
the ECM or power down the controller.

Powering down the electronic control module can be
achieved by the operation of the keyswitch into sleep
mode. The electronic control module can be powered
down by isolating the power supply to the electronic
control module.

Sensors and Electrical
Components

SMCS Code: 1900; 7400

The illustrations within the following sections are
typical location of the sensors or electrical
components for an industrial engine. Specific
engines may appear different due to differences in
applications.

M0080243-01 27

Operation Section

Sensors and Electrical Components

Illustration 21 g06169874

Typical example

(1) Refrigerant compressor
(2) Boost pressure sensor
(3) Manifold temperature sensor
(4) Fuel temperature sensor

(5) Fuel pressure sensor
(6) Electronic control module
(7) Starting motor
(8) Oil pressure sensor

(9) Atmospheric pressure sensor
(10) Primary speed/timing sensor
(11) Alternator
(12) Secondary Speed/timing sensor

28 M0080243-01

Operation Section
Sensors and Electrical Components

Illustration 22 g06169876

Typical example

(13) Coolant temperature sensor

M0080243-01 29

Operation Section

Engine Diagnostics

Engine Diagnostics

i06217555

Self-Diagnostics

SMCS Code: 1000; 1900; 1901; 1902

Perkins Electronic Engines can perform a self­diagnostics 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 Perkins
Electronic Service Tool (EST).

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.

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.

i06217559

Diagnostic Lamp

SMCS Code: 1000; 1900; 1901; 1902; 7451

A diagnostic lamp is used to indicate the existence of
an active fault. A fault diagnostic code will remain
active until the problem is repaired. The diagnostic
code may be retrieved by using the electronic service
tool.

i06217560

Fault Logging

SMCS Code: 1000; 1900; 1901; 1902

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 cannot be cleared from the
memory of the ECM without using a factory
password: Overspeed, low engine oil pressure, high
engine coolant temperature, and aftertreatment
codes.

i06217575

Engine Operation with Active
Diagnostic Codes

SMCS Code: 1000; 1900; 1901; 1902

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

Note: If the customer has selected “DERATE” and
there is a low oil pressure condition, engine power
will be limited until the problem is corrected. If the oil
pressure is within the normal range, the engine may
be operated at the rated speed and load. However,
maintenance should be performed as soon as
possible.

The active diagnostic code should be investigated.
The cause of the problem should be corrected as
soon as possible. If the cause of the active diagnostic
code is repaired and there is only one active
diagnostic code, the diagnostic lamp will turn off.

Operation of the engine and performance of the
engine can be limited as a result of the active
diagnostic code that is generated. Acceleration rates
may be lower. Refer to the Troubleshooting Guide for
more information on the relationship between these
active diagnostic codes and engine performance.

30 M0080243-01

Operation Section
Engine Operation with Intermittent Diagnostic Codes

i06217564

Engine Operation with
Intermittent Diagnostic Codes

SMCS Code: 1000; 1900; 1901; 1902

If a diagnostic lamp illuminates during normal engine
operation and the diagnostic lamp shuts off, an
intermittent fault may have occurred. If a fault has
occurred, the fault will be logged into the memory of
the Electronic Control Module (ECM).

In most cases, an intermittent code will not require
the engine to be stopped. The operator should
retrieve the logged fault codes and reference the
appropriate information in order to identify the nature
of the event. The operator should log any observation
that could have caused the lamp to light.

• Low power

• Limits of the engine speed

• Excessive smoke

This information can be useful to help troubleshoot
the situation. The information can also be used for

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

M0080243-01 31

Operation Section

Engine Starting

Engine Starting

i06217584

Before Starting Engine

SMCS Code: 1000; 1400; 1450

Perform the required daily maintenance and other
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for more

information.

• For the maximum service life of the engine, make
a thorough inspection before the engine is started.
Look for the following items: oil leaks, coolant
leaks, loose bolts and trash buildup. Remove trash
buildup and arrange for repairs, as needed.

• Inspect the aftercooler for loose connections and
for debris buildup.

• Inspect the cooling system hoses for cracks and
for loose clamps.

• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage.

• Inspect the wiring for loose connections and for
worn wires or frayed wires.

• Check the fuel supply. Drain water from the water
separator (if equipped). Open the fuel supply
valve.

NOTICE

All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.

• If there is a “DO NOT OPERATE” warning tag or

similar attached to the start switch or the controls,
do not start the engine or move any controls.

• Ensure that the areas around the rotating parts are
clear.

• All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
and/or missing guards.

• Disconnect any battery chargers that are not
protected against the high current drain that is
created when the electric starting motor (if
equipped) is engaged. Check electrical cables and
check the battery for poor connections and for
corrosion.

• Reset all of the shutoffs or alarm components.

• Check the engine lubrication oil level. Maintain the
oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.

• Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
the coolant level to the “FULL” mark on the coolant
recovery tank.

• If the engine is not equipped with a coolant
recovery tank, maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
the engine is equipped with a sight glass, maintain
the coolant level in the sight glass.

• Observe the air cleaner service indicator (if
equipped). Service the air cleaner when the yellow
diaphragm enters the red zone, or when the red
piston locks in the visible position.

• Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
any electrical loads.

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.

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

to the outside.

i06217593

Cold Weather Starting

SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900

Startability will be improved at temperatures below
10°C (50°F) from the use of a cylinder block coolant
heater or from other means that are used to heat the

crankcase oil. Some engine applications use a jacket
water heater to improve startability. Use of a jacket
water heater will help reduce white smoke and
misfire during start-up in cold weather.

32 M0080243-01

Operation Section
Starting the Engine

Note: If the engine has not been run for several
weeks, fuel may have drained. Air may have moved
into the filter housing. Also, when fuel filters have
been changed, some air will be left in the filter
housing. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” (Maintenance
Section) for more information on priming the fuel
system.

Ether Injection System (If
Equipped)

The ether injection system is controlled by the ECM.
The ECM monitors the coolant temperature, intake
air temperature, ambient air temperature, and
barometric pressure to determine when ether
injection is needed. At sea level, ether will be used if
any of the temperatures fails to exceed 0° C (32° F).
This temperature is subject to an increase as
barometric pressure increases.

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

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

Follow the procedure in this Operation and
Maintenance Manual, “Starting the Engine”.

During the key on, all warning lamps will illuminate
for a few seconds, in order to test the circuits. If

any lamps do not illuminate, check the bulbs and
replace as necessary.

NOTICE

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

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

allow the starting motor to cool before attempting to
start the engine again.

3. Push the start button or turn the ignition switch to
the START position in order to crank the engine.

Do not push down or hold the throttle down while
the engine is cranked. The system will
automatically provide the correct amount of fuel
that is needed to start the engine.

4. If the engine fails to start within 30 seconds,
release the start button, or the ignition switch. Wait
for 2 minutes in order to allow the starting motor to
cool before attempting to start the engine again.

NOTICE

Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine rpm until the oil
pressure gauge indicates normal. If oil pressure is
not indicated on the gauge within 15 seconds, DO
NOT operate the engine. STOP the engine, investi­gate and correct the cause.

i06217596

Starting the Engine

SMCS Code: 1000; 1450

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

to the outside.

Starting the Engine

Refer to the Owners Manual of the OEM for your type
of controls. Use the following procedure to start the
engine.

1. Remove all driven equipment loads in order to
allow the engine to start faster, and to reduce the
draining of the battery.

2. Turn the ignition switch to the ON position.

5. Do not apply a load to the engine for approximately

3 minutes. Run the engine until the water
temperature gauge has begun to rise. Check all
gauges during the warm-up period.

Note: Oil pressures and fuel pressures should be in
the normal range on the instrument panel. Engines
that are equipped with “WARNING” lamps do not
have an operating range. The “WARNING and
DIAGNOSTIC” lamp (if equipped) will flash while the
engine is cranking. The lamp should turn off after
sufficient engine oil pressure or fuel pressure is
achieved. Do not apply a load to the engine until the
oil pressure gauge indicates at least normal
pressure. Inspect the engine for leaks and/or unusual
noises.

If the engine is operated with a low load, the engine
will reach normal operating temperature sooner than
idling the engine with no load.

Starting Problems

An occasional starting problem may be caused by
one of the following items:

• Low battery charge

M0080243-01 33

Operation Section

Starting with Jump Start Cables

• Lack of fuel

• Problem with the wiring harness

If the engine fuel system has been run dry, fill the fuel
tank and prime the fuel system. Refer to the
Operation and Maintenance Manual, “Fuel System ­Prime” topic (Maintenance Section).

Problems with the Wiring Harness

3. Start the engine. If the engine does not start, check

for a diagnostic code and consult your Perkins
distributor.

i06217616

Starting with Jump Start
Cables

(Do Not Use This Procedure in
Hazardous Locations that have
Explosive Atmospheres)

SMCS Code: 1000; 1401; 1402; 1900

The connection of battery cables to a battery and
the disconnection of battery cables from a battery
may cause an explosion which may result in in­jury or death. The connection and the disconnec­tion of other electrical equipment may also cause
an explosion which may result in injury or death.
The procedures for the connection and the dis­connection of battery cables and other electrical
equipment should only be performed in a nonex­plosive atmosphere.

Illustration 23 g01248812

ECM Connector J2/P2

Locate the ECM. Check the connector in order to
ensure that the connector is secure. Lightly pull each

of the wires in the chassis harness.

1. Pull each wire with approximately 4.5 kg (10 lb) of
force. The wire should remain in the connector.

2. If a wire is loose, push the wire back into the
connector. Pull the wire again in order to ensure
that the wire is secure.

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

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

Note: If possible, first diagnose the reason for the

starting failure. Refer to Troubleshooting, “Engine
Does Not Crank and Engine Cranks But Does Not
Start” for further information. Make any necessary
repairs.

If the engine will not start only due to the condition of
the battery, perform one of the following procedures:

• Charge the battery

• Start the engine using another battery with jump­start cables

The condition of the battery can be rechecked after
the engine has been switched OFF.

34 M0080243-01

Operation Section
After Starting Engine

Using a battery source with the same voltage as the

NOTICE

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 engines accessories.

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

3. Connect one negative end of the jump-start cable
to the negative terminal of the electrical source.
Connect the other negative end of the jump-start
cable to the engine block or to the chassis ground.
This procedure helps to prevent potential sparks
from igniting the combustible gases that are
produced by some batteries.

i06217669

After Starting Engine

SMCS Code: 1000

Note: In temperatures from 0 to 60°C (32 to 140°F),

the warm-up time is approximately 3 minutes. In
temperatures below 0°C (32°F), additional warm-up
time may be required.

Note: Ensure that the self test for the monitoring
system (if equipped) is completed before operating
the engine under load.

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

• Check for any fluid or air leaks (no load on the
engine) before operating the engine under load.

• Operate the engine with no load until all systems
achieve operating temperatures. Check all gauges
during the warm-up period.

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

Note: The engine ECM must be powered before the
starting motor is operated or damage can occur.

4. Start the engine in the normal operating
procedure. Refer to this Operation and
Maintenance Manual, “Starting the Engine”.

5. Immediately after the engine is started, disconnect
the jump-start cables in reverse order.

After jump starting, the alternator may not be able to
recharge batteries to full capacity that are severely
discharged. The batteries must be replaced or
charged to the correct voltage with a battery charger
after the engine is stopped. Many batteries which are
considered unusable are still rechargeable. Refer to
Operation and Maintenance Manual, “Battery ­Replace” and Testing and Adjusting Manual, “Battery

- Test”.

M0080243-01 35

Operation Section

Engine Operation

Engine Operation

i06217673

Engine Operation

SMCS Code: 1000

Correct operation and maintenance are key factors in
obtaining the maximum life and economy of the
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be

minimized and engine service life can be maximized.

Allow the engine to warn up before applying load.

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

i06217680

Engaging the Driven
Equipment

SMCS Code: 1000

If the load varies, or if the load is cyclic, the governor
will adjust the engine rpm, as needed.

Extended operation at a reduced load may cause
increased oil consumption and carbon buildup in the
cylinders. This carbon buildup results in a loss of
power and/or poor performance. When the engine is
operated at a reduced load, fully load the engine
every 4 hours in order to burn excess carbon from
the cylinders.

2. Engage the driven equipment. Begin operating the
engine at low load. Check the gauges and check
the equipment for proper operation. Check the
gauges and check the equipment frequently while
the engine is operating under load.

i06217701

Fuel Conservation Practices

SMCS Code: 1000; 1250

The efficiency of the engine can affect the fuel
economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
in order to attain optimum performance for the life of
the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel
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
Operations and Maintenance Manual, “Fuel
Recommendations”for further information.

• Avoid unnecessary idling.

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

• Observe the service indicator frequently. Keep the
air cleaner elements clean.

• Ensure that the turbochargers are operating
correctly. For more information refer to this
Operation and Maintenance Manual ,
“Turbocharger - Inspect”

Industrial Engines

1. When the engine is operating, check the engine

gauges. The engine gauges should be in the
normal range before you engage the driven
equipment.

• Maintain a good electrical system.

One faulty battery cell will overwork the alternator.
This fault will consume excess power and excess
fuel.

• The belts must be in good condition. Refer to the
Systems Operation, Testing and Adjusting, “Belts ­Adjust” 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.

36 M0080243-01

Operation Section
Fuel Conservation Practices

• Cold engines consume excess fuel. Utilize heat
from the jacket water system and the exhaust
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without a water temperature regulator. All
of these items will help maintain operating
temperatures.

M0080243-01 37

Operation Section

Cold Weather Operation

Cold Weather Operation

i06219089

Radiator Restrictions

SMCS Code: 1353; 1396

Perkins discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow

restriction can cause the following conditions:

• High exhaust temperatures

• Power loss

• Excessive fan usage

• Reduction in fuel economy

Reducing air flow over components will also affect
under hood temperatures.

If an airflow restriction device must be used, the
device should have a permanent opening directly in

line with the fan hub. The device must have a
minimum opening dimension of at least 770 cm

(120 in2).

A centered opening that is directly in line with the fan
hub is specified in order to prevent an interrupted
airflow on the fan blades. Interrupted airflow on the
fan blades could cause a fan failure.

Perkins recommends a warning device for the inlet
manifold temperature and/or the installation of an
inlet air temperature gauge. The warning device for
the inlet manifold temperature should be set at 75 °C
(167 °F). The inlet manifold air temperature should
not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential
engine damage.

Fuel and the Effect from Cold
Weather

SMCS Code: 1000; 1250; 1280

Note: Only use grades of fuel that are recommended

by Perkins. Refer to this Operation and Maintenance
Manual, “Fluid Recommendations”.

Properties of the diesel fuel can have a significant
effect on the engine cold start capability. It is critical
that the low temperature properties of diesel fuel are
acceptable for the minimum ambient temperature the
engine will see in operation.

The following properties are used to define fuel low
temperature capability:

• Cloud point

2

i06219102

• Cold Filter Plugging Point (CFPP)

• Pour point

The cloud point of the fuel is the temperature at
which waxes naturally found in the diesel fuel begin
to form crystals. The cloud point of the fuel must be
below lowest ambient temperature to prevent filters
from plugging.

Cold Filter Plugging Point is a temperature at which a
particular fuel will pass through a standardized
filtration device. This CFPP gives an estimate of the
lower operability temperature of fuel

Pour point is the last temperature before the fuel flow
stops and waxing of the fuel will start.

Be aware of these properties when diesel fuel is
purchased. Consider the average ambient air
temperature for the engines application. Engines that
are fueled in one climate may not operate well if the
engines are shipped to colder climate. Problems can
result due to changes in temperature.

Before troubleshooting for low power or for poor
performance in the winter, check the fuel for waxing.

The following components can provide a means of
minimizing fuel waxing problems in cold weather:

• Fuel heaters, which may be an OEM option

• Fuel line insulation, which may be an OEM option

Winter and arctic grades of diesel fuel are available in
the countries and territories with severe winters. For

more information refer to the Operation and
Maintenance Manual, “Fuel For Cold Weather

Operation”

Another important fuel property which can affect cold
start and operation of diesel engine is the Cetane
number. Detail and requirements of this property are
given in this Operation and Maintenance Manual,
“Fluid Recommendations”.

i06219103

Fuel Related Components in
Cold Weather

SMCS Code: 1000; 1250; 1280

Fuel Tanks

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

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

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

supply pipe.

38 M0080243-01

Operation Section
Fuel Related Components in Cold Weather

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

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

• Weekly

• Oil changes

• Refueling of the fuel tank

This draining will help prevent water and/or sediment
from being pumped from the fuel storage tank and
into the engine fuel tank.

Fuel Heaters

Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in order for the fuel to be heated before

the fuel enters the primary fuel filter.

Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater
with a large heating surface. The fuel heater should
be practical in size. Small heaters can be too hot due
to the limited surface area.

Disconnect the fuel heater in warm weather.

Note: Fuel heaters that are controlled by the water
temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters that are
not controlled by the water temperature regulator can
heat the fuel in excess of 65° C (149° F). A loss of
engine power can occur if the fuel supply
temperature exceeds 37° C (100° F).

Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
the fuel in warm-weather operation.

For further information on fuel heaters, consult a
Perkins distributor.

M0080243-01 39

Operation Section

Engine Stopping

Engine Stopping

i06219104

Stopping the Engine

SMCS Code: 1000

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. Allow the
engine to cool for 5 minutes.

2. Stop the engine after the cool down period
according to the shutoff system on the engine.
Turn the ignition key switch to the OFF position. If
necessary, refer to the instructions that are
provided by the OEM.

i06219122

Manual Stop Procedure

SMCS Code: 1000; 7418

2. Run the engine for at least 3 minutes.

3. After the cool down period, turn the start switch to

the OFF position.

i06219131

After Stopping Engine

SMCS Code: 1000

Note: Before checking the engine oil, do not operate

the engine for at least 10 minutes. The delay is
needed in order to allow the engine oil to return to the
oil pan.

• Check the crankcase oil level. Maintain the oil

level between the “ADD” mark and the “FULL”
mark on the oil level gauge.

• If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.

• Note the service hour meter reading. Perform the
maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.

• Replenish the fuel tank in order to help prevent
accumulation of moisture in the fuel. Do not overfill
the fuel tank.

NOTICE

Only use antifreeze/coolant mixtures recommended
in the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause

engine damage.

• Allow the engine to cool. Check the coolant level.

Stopping the engine immediately after it has been

NOTICE

working under load can result in overheating and ac­celerated wear of the engine components.

If the engine has been operating at high rpm and/or
high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be­fore stopping the engine.

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

Note: Individual applications 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 so that the
engine has no more than 30% power.

• If freezing temperatures are expected, check the
coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.

40 M0080243-01

Maintenance Section
Refill Capacities

Maintenance Section

Refill Capacities

Refill Capacities and
Recommendations

SMCS Code: 1348; 1395; 7560

Refill Capacities

Lubricant Refill Capacity

i06937316

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 extra oil. Refer to the OEM specifications for
the capacity of the auxiliary oil filter.

Table 2

2000 Series Industrial Engines

Approximate Refill Capacities

Oil Sump

Standard pan 34 L (36 qt) 43 L (45 qt)

Center pan 60 L (63 qt) 62 L (66 qt)

Deep pan 68 L (72 qt) 70 L (74 qt)

(1)

These values are approximate capacities for the crankcase oil
sump which include the standard oil filters that are installed at
the factory. Engines with auxiliary oil filters will require extra oil.
Refer to the OEM specifications for the capacity of the auxiliary
oil filter.

(1)

Engine with 1

Filter

Engine with 2

Filters

Coolant Refill Capacity

To maintain the cooling system, the total cooling
system capacity must be known. The capacity of the
total cooling system will vary. The capacity will
depend on the size of the radiator (capacity). Table 3
should be completed by the customer for the
maintenance of the cooling system.

Table 3

Approximate Capacity of the Cooling System

Illustration 24 g02300456

Standard pan

Illustration 25 g02300473

Center pan

Illustration 26 g02300474

Deep pan

Compartment or

System

Total Cooling System

(1)

(1)

The total cooling system capacity includes the following compo­nents: The engine block, the radiator, and all coolant hoses and
lines.

Liters

Quarts

Recommendation

Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for information about the

fluids which are acceptable for this engine.

i06219169

Fluid Recommendations

SMCS Code: 1280; 1348; 1395; 7560

General Lubricant Information

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

• API American Petroleum Institute

M0080243-01 41

Maintenance Section

Fluid Recommendations

• SAE Society Of Automotive Engineers Inc.

Licensing

The Engine Oil Licensing and Certification System by
the American Petroleum Institute (API). For detailed
information about this system, see the latest edition
of the “API publication No. 1509”. Engine oils that
bear the API symbol are authorized by API.

Illustration 27 g03813274

Typical API symbol

Terminology

Certain abbreviations follow the nomenclature of
“SAE J754”. Some classifications follow “SAE J183”
abbreviations, and some classifications follow the
“EMA Recommended Guideline on Diesel Engine

Oil”. 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).

API CI-4 Plus provide two design improvements over
API CI-4 oil specification, soot viscosity control and
product shear stability.

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 and CH-4.

Lubricant Viscosity Recommendations
for Direct Injection (DI) Diesel Engines

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

Refer to illustration 28 (minimum temperature) in
order to determine the required oil viscosity for
starting a cold engine.

Refer to illustration 28 (maximum temperature) in
order to select the oil viscosity for engine operation at
the highest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that is
available to meet the requirement for the temperature

at start-up.

Engine Oil

Commercial Oils

Perkins require the use of the following specifica­tion of engine oil. Failure to use the appropriate
specification of engine oil will reduce the life of
your engine.

Table 4

Preferred Oil Specification Acceptable

API CI-4 Plus API CI-4

API CI-4 Plus meets the designed life of the product,
the use of the appropriate engine oil is essential.

NOTICE

Oil Specification

42 M0080243-01

Maintenance Section
Fluid Recommendations

• At the specified interval, service the engine. Use
new oil and install a new oil filter.

• Perform maintenance at the intervals that are
specified in the Operation and Maintenance
Manual, “Maintenance Interval Schedule”.

Oil analysis

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

program.

The oil analysis is a diagnostic tool that is used to
determine oil performance and component wear
rates. Contamination can be identified and measured

by using oil analysis. The oil analysis includes the
following tests:

• The Wear Rate Analysis monitors the wear of the

Illustration 28 g03329707

Lubricant Viscosities

Supplemental heat is recommended 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. The requirement also depends on the
parasitic load and other factors. Cold soaked starts
occur when the engine has not been operated for a
longtime. This interval will allow the oil to become
more viscous due to cooler ambient temperatures.

Aftermarket Oil Additives

Perkins does not recommend the use of aftermarket
additives in oil. The use of aftermarket additives in
order to achieve the engines maximum service life or

rated performance is not necessary. Fully formulated,
finished oils consist of base oils and of commercial

additive packages. Additive packages are blended
into the base oils at precise percentages in order to
provide finished oils with performance characteristics
that meet industry standards.

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

with the finished oil. This failure could produce sludge
in the crankcase. Perkins discourages the use of
aftermarket additives in finished oils.

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

• See the appropriate “Lubricant Viscosities”. Refer
to the illustration 28 in order to find the correct oil
viscosity grade for your engine.

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

• Tests are conducted in order to detect
contamination of the oil by water, glycol, or fuel.

• The Oil Condition Analysis determines the loss of
the oils lubricating properties. An infrared analysis
is used to compare the properties of new oil to the
properties of the used oil sample. This analysis
allows technicians to determine the amount of
deterioration of the oil during use. This analysis
also allows technicians to verify the performance
of the oil according to the specification during the
entire oil change interval.

i06288553

Fluid Recommendations

SMCS Code: 1280; 1348; 1395; 7560

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.

M0080243-01 43

Maintenance Section

Fluid Recommendations

Frequently check the specific gravity of the coolant

NOTICE

for proper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

• Contamination of the cooling system

• Overheating of the engine

• Foaming of the coolant

NOTICE

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.

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

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

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

Water

Water is used in the cooling system in order to
transfer heat.

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

• Local water utility company

• Agricultural agent

• Independent laboratory

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

• Leakage of the water pump seal

• Plugging of radiators, coolers, and small passages

Distilled water or deionized water is
recommended for use in engine cooling systems.

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

If distilled water or deionized water is not available,
use water with the properties that are listed in Table 5
.

Table 5

Acceptable Water

Property

Chloride (Cl) 40 mg/L

Sulfate (SO

Total Hardness

Total Solids

Acidity pH of 5.5 to 9.0

) 100 mg/L

4

Maximum Limit

170 mg/L

340 mg/L

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).

44 M0080243-01

Maintenance Section
Fluid Recommendations

Most conventional antifreezes use ethylene glycol.
Propylene glycol may also be used. In a 1:1 mixture
with water, ethylene and propylene glycol provide
similar protection against freezing and boiling. Refer
to Table 6 and refer to table 7 .

Table 6

Ethylene Glycol

Concentration Freeze Protection

50 Percent

60 Percent

−36 °C (−33 °F)

−51 °C (−60 °F)

NOTICE

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

Table 7

Propylene Glycol

Concentration Freeze Protection

50 Percent

−29 °C (−20 °F)

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

Coolant Recommendations

• ELC Extended Life Coolant

• SCA Supplement Coolant Additive

• ASTM American Society for Testing and
Materials

The following two coolants are used in Perkins diesel
engines:

Preferred – Perkins ELC

Acceptable – A commercial heavy-duty antifreeze

that meets “ASTM D6210 ” specifications

The Perkins 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

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

optimum heavy-duty performance as an antifreeze.
This ratio may be increased to 1:2 water to glycol if
extra freezing protection is required.

A mixture of SCA inhibitor and water is acceptable
but will not give the same level of corrosion, boiling
and, freezing protection as ELC. Perkins
recommends a 6 percent to 8 percent concentration
of SCA in those cooling systems. Distilled water or
deionized water is preferred.

Table 8

Coolant Service Life

Coolant Type

Perkins ELC

Commercial Heavy-Duty Anti-

freeze that meets “ASTM

Commercial SCA inhibitor and

(1)

Use the interval that occurs first. The cooling system must also
be flushed out at this time.

D6210”

Water

Service Life

6,000 Service Hours or Three

3000 Service Hours or Two Year

3000 Service Hours or One Year

(1)

Years

ELC

Perkins provides ELC for use in the following
applications:

• Heavy-duty spark ignited gas engines

• Heavy-duty diesel engines

• Automotive applications

The anti-corrosion package for ELC is different from
the anti-corrosion package for other coolants. ELC is
an ethylene glycol base coolant. However, ELC
contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrite. Perkins ELC has
been formulated with the correct amount of these

additives in order to provide superior corrosion
protection for all metals in engine cooling systems.

ELC is available in a premixed cooling solution with
distilled water. ELC is a 1:1 mixture. The Premixed

ELC provides freeze protection to −36 °C (−33 °F).
The Premixed ELC is recommended for the initial fill

of the cooling system. The Premixed ELC is also
recommended for topping off the cooling system.

Do not use a commercial coolant/antifreeze that only

NOTICE

meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light automotive
applications.

M0080243-01 45

Maintenance Section

Fluid Recommendations

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

ELC Cooling System Maintenance

Correct additions to the Extended Life
Coolant

NOTICE

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

Mixing Extended Life Coolant with other products re­duces the Extended Life Coolant service life. Failure

to follow the recommendations can reduce cooling
system components life unless appropriate corrective
action is performed.

In order to maintain the correct balance between the
antifreeze and the additives, you must maintain the

recommended concentration of ELC. Lowering the
proportion of antifreeze lowers the proportion of
additive. Lowering the ability of the coolant to protect
the system will form pitting, from cavitation, from
erosion, and from deposits.

NOTICE

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

Do not use standard supplemental coolant additive
(SCA).

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

ELC Cooling System Cleaning

Changing to Perkins ELC

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

NOTICE
Care must be taken to ensure that all fluids are con­tained during performance of inspection, mainte-

nance, testing, adjusting and the 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.

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to local

regulations.

3. Fill the cooling system with a 33 percent solution of

Perkins ELC and operate the engine, ensure that
the thermostat opens. Stop the engine and allow
the engine to cool. Drain the coolant.

Note: Use distilled or deionized water in the solution.

4. Again, fill the cooling system with a 33 percent

solution of Perkins ELC and operate the engine
ensure that the thermostat opens. Stop the engine
and allow to cool.

5. Drain the drain the cooling system.

NOTICE
Incorrect or incomplete flushing of the cooling system

can result in damage to copper and other metal
components.

Note: If the cooling system is already using ELC,
cleaning agents are not required to be used at the
specified coolant change interval. Cleaning agents
are only required if the system has been
contaminated by the addition of some other type of
coolant or by cooling system damage.

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

Before the cooling system is filled, the heater control
(if equipped) must be set to the HOT position. Refer
to the OEM in order to set the heater control. After

the cooling system is drained and the cooling system
is refilled, operate the engine until the coolant level
reaches the normal operating temperature and until
the coolant level stabilizes. As needed, add the

coolant mixture in order to fill the system to the
specified level.

6. Fill the cooling system with the Perkins Premixed

ELC. Operate the engine. Ensure that all coolant
valves open then stop the engine. When cool
check the coolant level.

ELC Cooling System Contamination

NOTICE
Mixing ELC with other products reduces the effective-

ness of the ELC and shortens the ELC service life.
Use only Perkins Products for premixed or concen-

trate 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:

46 M0080243-01

Maintenance Section
Fluid Recommendations

• Drain the cooling system into a suitable container.
Dispose of the coolant according to local
regulations. Flush the system with a 5 to 10
percent solution of Perkins ELC. 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 Heavy­Duty Coolant. Treat the system with an SCA.
Change the coolant at the interval that is
recommended for the conventional Heavy-Duty
Coolant.

Commercial Heavy-Duty Antifreeze and
SCA

NOTICE

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

Table 10 is an example for using the equation that is
in Table 9 .

Table 10

Example Of The Equation For Adding The SCA To The Heavy-

Total Volume of the
Cooling System (V)

15 L (4 US gal) × 0.045 0.7 L (24 oz)

Duty Coolant At The Initial Fill

Multiplication

Factor

Amount of SCA
that is Required

(X)

Adding The SCA to The Heavy-Duty
Coolant For Maintenance

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

Test the antifreeze periodically for the concentration
of SCA. For the interval, refer to the Operation and
Maintenance Manual, “Maintenance Interval

Schedule” (Maintenance Section). Cooling System
Supplemental Coolant Additive (SCA) Test/Add.

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

amount of SCA that is needed.

Never operate an engine without water temperature

NOTICE

regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
correct operating temperature. Cooling system prob­lems can develop without water temperature
regulators.

Check the antifreeze (glycol concentration) in order
to ensure adequate protection against boiling or
freezing. Perkins recommends the use of a
refractometer for checking the glycol concentration. A
hydrometer should not be used.

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

Additions of SCA are based on the results of the test.
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 9 to determine the
amount of SCA that is required when the cooling
system is initially filled.

Table 9

Equation For Adding The SCA To The Heavy-Duty Coolant At

The Initial Fill

V × 0.045 = X

V is the total volume of the cooling system.

Use the equation that is in Table 11 to determine the
amount of SCA that is required, if necessary:

Table 11

Equation For Adding The SCA To The Heavy-Duty Coolant

V is the total volume of the cooling system.

X is the amount of SCA that is required.

For Maintenance

V × 0.014 = X

Table 12 is an example for using the equation that is
in Table 11 .

Table 12

Example Of The Equation For Adding The SCA To The Heavy-

Total Volume of the
Cooling System (V)

15 L (4 US gal) × 0.014 0.2 L (7 oz)

Duty Coolant For Maintenance

Multiplication

Factor

Amount of SCA
that is Required

(X)

Cleaning the System of Heavy-Duty
Antifreeze

• Clean the cooling system after used coolant is
drained or before the cooling system is filled with
new coolant.

X is the amount of SCA that is required.

M0080243-01 47

Maintenance Section

Fluid Recommendations

• Clean the cooling system whenever the coolant is
contaminated or whenever the coolant is foaming.

i06795193

Fluid Recommendations

(General Fuel Information)

SMCS Code: 1280; 1348; 1395; 7560

• Glossary

• ISO International Standards Organization

• ASTM American Society for Testing and Materials

• HFRR High Frequency Reciprocating Rig for
Lubricity testing of diesel fuels

• FAME Fatty Acid Methyl Esters

• CFR Co-ordinating Fuel Research

• LSD Low Sulfur Diesel

• ULSD Ultra Low Sulfur Diesel

• RME Rape Methyl Ester

Satisfactory engine performance depends on the use
of a good quality fuel. The use of a good quality fuel
will give the following results: long engine life and
acceptable exhaust emissions levels. The fuel must
meet the minimum requirements that are stated in
table 13 .

NOTICE

The footnotes are a key part of the Perkins Specifica­tion for Distillate Diesel Fuel Table. Read ALL of the

footnotes.

• SME Soy Methyl Ester

• EPA Environmental Protection Agency of the
United States

General Information

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

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

NOTICE

NOTICE

Diesel Fuel Requirements

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

specifications that are published by governments and
technological societies.

Perkins Specification for Distillate Diesel Fuel in table
13 provides a known reliable baseline to judge the
expected performance of distillate diesel fuels that
are derived from conventional sources.

48 M0080243-01

Maintenance Section
General Fuel Information

Table 13

Perkins Specification for Distillate Diesel Fuel

Property UNITS Requirements “ASTM Test” “ISO Test”

Aromatics %Volume 35% maximum “D1319” “ISO 3837”

Ash %Weight 0.01% maximum “D482” “ISO 6245”

Carbon Residue on 10%

%Weight 0.35% maximum “D524” “ISO 4262”

Bottoms

Cetane Number

(1)

Cloud Point °C The cloud point must not ex-

-

40 minimum “D613 or D6890” “ISO 5165”

“D2500” “ISO 3015”
ceed the lowest expected
ambient temperature.

Copper Strip Corrosion

-

Distillation °C 10% at 282 °C (539.6 °F)

No. 3 maximum “D130” “ISO 2160”

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

Density at 15 °C (59 °F)

(2)

Kg / M

3

800 minimum and 860
maximum

No equivalent test “ISO 3675” or “ISO 12185”

Flash Point °C legal limit “D93” “ISO 2719”

Thermal Stability

-

Minimum of 80% reflec-

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

Pour Point °C 6 °C (10°F)

“D97” “ISO 3016”
Minimum below ambient
temperature

Sulfur %mass

Kinematic Viscosity

(4)

“MM2/S (cSt)” The viscosity of the fuel that

(3)

“D5453 or /D2622” “ISO 20846” or “ISO 20884”

“D445” “ISO 3405”

is delivered to the fuel injec­tion pump. “1.4 minimum
and /4.5 maximum”

Water and sediment % weight 0.05% maximum “D1796” “ISO 3734”

Water % weight 0.05% maximum “D1744” No equivalent test

Sediment % weight 0.05% maximum “D473” “ISO 3735”

Gums and Resins

(5)

mg/100mL 10 mg per 100 mL

“D381” “ISO 6246”
maximum

Lubricity correctedwear

mm

0.46 maximum “D6079” “ISO 12156-1”

scar diameter at 60 °C
(140 °F).

Fuel cleanliness

(1)

(2)

(6)

(7)

-

“ISO”18/16/13 “7619” “ISO 4406”

In order to insure minimum cetane number of 40 a distillate diesel fuel should have minimum cetane index of 44 when ASTM D4737 test
method is used. A fuel with a higher cetane number is recommended to operate at a higher altitude or in cold weather.
Density range allowed includes summer and winter diesel fuel grades. Fuel density varies depending on the sulfur level where high sulfur
fuels have higher densities. Some unblended alternative fuels have lower densities which are acceptable, if all the other properties meet this
specification.

(3)

Regional regulations, national regulations, or international regulations can require a fuel with a specific sulfur limit. Consult all applicable reg­ulations before selecting a fuel for a given engine application. LSD fuel with less than 0.05 percent (≤ 500 ppm (mg/kg)) sulfur is recom­mended for use in these engine models. Diesel fuel with more than 0.05 percent (≥ 500 ppm (mg/kg)) sulphur can be used only where
allowed by legislation. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal compo­nents. Fuel sulfur levels above 0.05% may significantly shorten the oil change interval. For additional information, refer to General lubricant
Information.

(continued)

M0080243-01 49

Maintenance Section

General Fuel Information

(Table 13, contd)

(4)

The values of the fuel viscosity 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 meet the maximum viscosity requirements at 40° C (104° F) of either the "ASTM D445" test method or
the "ISO 3104" test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain 1.4 cSt or greater viscosity at
the fuel injection pump. Fuels with a high viscosity might require fuel heaters to lower the viscosity to 4.5 cSt at the fuel injection pump.

(5)

Follow the test conditions and procedures for gasoline (motor).

(6)

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

(7)

Recommended cleanliness level for fuel as dispensed into machine or engine fuel tank is "ISO 18/16/13 or cleaner as per ISO 4406. Refer to
the "Contamination Control Recommendations for Fuels" in this chapter.

Operating with fuels that do not meet the Perkins rec-

NOTICE

ommendations can cause the following effects: Start­ing difficulty, poor combustion, deposits in the fuel
injectors, reduced service life of the fuel system, de­posits in the combustion chamber and reduced serv­ice life of the engine.

Engines that are manufactured by Perkins are certi­fied with the fuel that is prescribed by the United
States Environmental Protection Agency. Engines
that are manufactured by Perkins are certified with
the fuel that is prescribed by the European Certifica­tion and other regulatory agencies. 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 Environmental Protection Agency (EPA) and
other appropriate regulatory agencies.

Diesel Fuel Characteristics

Perkins Recommendations

Cetane Number

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

Viscosity

Viscosity is the property of a liquid of offering
resistance to shear or flow. Viscosity decreases with
increasing temperature. This decrease in viscosity
follows a logarithmic relationship for normal fossil
fuel. The common reference is to kinematic viscosity.
Kinematic viscosity is the quotient of the dynamic
viscosity that is divided by the density. The
determination of kinematic viscosity is normally by
readings from gravity flow viscometers at standard
temperatures. Refer to “ISO 3104” for the test
method.

The viscosity of the fuel is significant because fuel
serves as a lubricant for the fuel system components.
Fuel must have sufficient viscosity to lubricate the
fuel system in both cold temperatures and hot
temperatures. If the kinematic viscosity of the fuel is
lower than 1.4 cSt at the fuel injection pump, damage
to the fuel injection pump can occur. This damage
can be excessive scuffing and seizure. Low viscosity
may lead to difficult hot restarting, stalling, and loss of
performance. High viscosity may result in seizure of
the pump.

Perkins recommends kinematic viscosities of 1.4 and

4.5 cSt that is delivered to the fuel injection pump. If a
fuel with a low viscosity is used, cooling of the fuel
may be required to maintain 1.4 cSt or greater
viscosity at the fuel injection pump. Fuels with a high
viscosity might require fuel heaters to lower the
viscosity to 4.5 cSt at the fuel injection pump.

Density

Cetane numbers more than 45 are normally expected
from current diesel fuel. However, a cetane number

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

can have a low cetane value. A minimum cetane
value of 40 is required during average starting

conditions. A higher cetane value may be required for
operations at high altitudes or in cold-weather
operations.

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

Density is the mass of the fuel per unit volume at a
specific temperature. This parameter has a direct
influence on engine performance and a direct
influence on emissions. This influence determines

the heat output from a given injected volume of fuel.
This parameter is quoted in the following kg/m3 at
15 °C (59 °F).

Perkins recommends a value of density of 841 kg/m3
to obtain the correct power output. Lighter fuels are
acceptable but these fuels will not produce the rated

power.

50 M0080243-01

Maintenance Section
General Fuel Information

Sulfur

The level of sulfur is governed by emissions
legislations. Regional regulation, national
regulations, or international regulations can require a
fuel with a specific sulfur limit. The sulfur content of
the fuel and the fuel quality must comply with all
existing local regulations for emissions.

LSD fuel with less than 0.05 percent (≤ 500 ppm (mg/
kg)) sulfur is recommended for use in these engine
models.

ULSD less than 0.0015% (≤15 PPM (mg/Kg)) sulphur
is acceptable to use in these engine models. The
lubricity of these fuels must not exceed wear scar
diameter of 0.46 mm (0.01811 inch) as per “ISO
12156-1”. Refer to “Lubricity” for more information.

Fuels with sulphur content higher than 0.05 percent
(500 PPM) can be used where allowed by legislation.

Fuel with a high sulfur content can cause engine
wear. High sulfur fuel will have a negative impact on
emissions of particulates. High sulfur fuel can be
used if the local emissions legislation will allow the
use. High sulfur fuel can be used in countries that do
not regulate emissions.

When only high sulfur fuels are available, high
alkaline lubricating oil must be used in the engine.
Alternatively, the lubricating oil change interval must
be reduced. Refer to Operation and Maintenance
Manual, “Fluid Recommendations (Lubricant
Information)” for information on sulfur in fuel.

Lubricity

Lubricity is the capability of the fuel to prevent pump
wear. The lubricity of the fluid describes the ability of
the fluid to reduce the friction between surfaces that

are under load. This ability reduces the damage that
is caused by friction. Fuel injection systems rely on
the lubricating properties of the fuel. Until fuel sulfur
limits were mandated, the lubricity of the fuel was
believed to be a function of fuel viscosity.

The lubricity has particular significance to the current
low viscosity fuel, low sulfur fuel, and low aromatic
fossil fuel. These fuels are made to meet stringent
exhaust emissions.

The lubricity of these fuels must not exceed wear
scar diameter of 0.46 mm (0.01811 inch). The fuel
lubricity test must be performed on an HFRR,
operated at 60 °C (140 °F). Refer to “ISO 12156-1”.

In the fuels which do not meet specified lubricity
requirement appropriate lubricity additive can be
used to enhance the lubricity of the fuel.

Perkins Diesel Fuel Conditioner U5MK8276 is the
approved additive refer to section, Perkins Diesel

Fuel Conditioner for more information.

Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier
can make recommendations for additives to use and

for the proper level of treatment.

Distillation

Distillation will give an indication of the mixture of
different hydrocarbons in the fuel. A high ratio of
lightweight hydrocarbons can affect the
characteristics of combustion.

Classification of the Fuels

Diesel engines have an ability to burn wide variety of
fuels. Below is a list of typically encountered fuel
specifications that have been assessed as to their
acceptability and are divided into following
categories:

Group 1: Preferred Fuels

The following fuel specifications are considered
acceptable.

• Fuels that meet the requirements that are listed in
the table 13 .

• “IS 1460 Bharat Stage 2, 3 and 4”

• “EN590 - Grades A to F and class 0 to 4”

• “ASTM D975 Grade No. 1-D and 2-D”

• “JIS K2204 Grades 1, 2 & 3 & Special Grade 3”
acceptable provided lubricity ware scar diameter
does not exceed of 0.46 mm (0.01811 inch) as
per “ISO 12156-1” .

• “BS2869 - Class A2 Off Highway Gas Oil, Red
Diesel”

Note: The lubricity of these fuels must not exceed
wear scar diameter of 0.46 mm (0.01811 inch) as per
“ISO 12156-1” . Refer to “Lubricity”.

Group 2: Aviation Kerosene Fuels

The fuels system has been qualified with fuel having

NOTICE

lubricity up to 0.46 mm (0.01811 inch) wear scar di­ameter as tested by “ISO 12156-1”. Fuel with higher
wear scar diameter than 0.46 mm (0.01811 inch) will
lead to reduced service life and premature failure of
the fuel system.

Following kerosene and jet fuel specifications are
acceptable alternative fuels, and may be used on a
contingency base for emergency or continuous use,
where standard diesel fuel is not available and where

legislation allows their use:

• “MIL-DTL-83133 NATO F34 (JP-8)”

• “MIL-DTL-83133 NATO F35”

M0080243-01 51

Maintenance Section

General Fuel Information

• “MIL-DTL-5624 NATO F44 (JP-5)”

• “MIL-DTL-38219 (USAF) (JP7)”

• “NATO XF63”

• “ASTM D1655 JET A”

• “ASTM D1655 JET A1”

NOTICE

These fuels are only acceptable when used with ap­propriate lubricity additive and must meet minimum
requirements that are listed in table 13 . The lubricity
of these fuels must not exceed wear scar diameter of

0.46 mm (0.01811 inch) as per “ISO 12156-1” . Refer
to “Lubricity” and Perkins Diesel Fuel Conditioner.

Note: Minimum cetane number of 40 is
recommended otherwise cold starting problems or
light load misfire might occur. Since jet fuel
specifications do not mention cetane requirements,
Perkins recommends that a fuel sample is taken to
determine the cetane number.

Note: Fuels must have minimum viscosity of 1.4 cSt
delivered to the fuel injection pump. Cooling of the
fuel may be required to maintain 1.4 cSt or greater
viscosity at the fuel injection pump. Perkins
recommends that the actual viscosity of the fuel, be
measured to determine if a fuel cooler is needed.
Refer to “Viscosity”.

Note: Rated power loss of up to 10 percent is
possible due to lower density and lower viscosity of
jet fuels compared to diesel fuels.

Biodiesel Fuel

Biodiesel is a fuel that can be defined as mono-alkyl
esters of fatty acids. Biodiesel is a fuel that can be
made from various feedstock. The most commonly
available biodiesel in Europe is Rape Methyl Ester
(REM). This biodiesel is derived from rapeseed oil.
Soy Methyl Ester (SME) is the most common
biodiesel in the United States. This biodiesel is

derived from soybean oil. Soybean oil or rapeseed oil
are the primary feedstocks. These fuels are together
known as Fatty Acid Methyl Esters (FAME).

Raw pressed vegetable oils are NOT acceptable for
use as a fuel in any concentration in compression
engines. Without esterification, these oils may gel in
the crankcase and the fuel tank. These fuels may not
be compatible with many of the elastomers that are
used in engines that are manufactured today. In
original forms, these oils are not suitable for use as a
fuel in compression engines. Alternate base stocks
for biodiesel may include animal tallow, waste
cooking oils, or various other feedstocks. To use any
of the products that are listed as fuel, the oil must be
esterified.

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

Biodiesel can be blended with distillate diesel fuel.
The blends can be used as fuel. The most commonly

available biodiesel blends are B5, which is 5 percent
biodiesel and 95 percent distillate diesel fuel. B20,
which is 20 percent biodiesel and 80 percent distillate
diesel fuel.

Note: The percentages given are volume-based. The
U.S. distillate diesel fuel specification “ASTM D975­09a” includes up to B5 (5 percent) biodiesel.

European distillate diesel fuel specification
“EN590:2010” includes up B7 (7 percent) biodiesel.

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

Specification Requirements

The neat biodiesel must conform to “EN14214” or
“ASTM D6751” (in the USA) and can only be blended

in mixture of up to 20 percent, by volume in
acceptable mineral diesel fuel meeting requirements
that are listed in table 13 or the latest edition of

“EN590” and “ASTM D 975” commercial standards.
This blend is commonly known as B20.

Biodiesel blends are denoted as “BXX” with “XX”
representing the content of neat biodiesel contained

in the blend with mineral diesel fuel (for example B5,
B10, B20).

In United States Biodiesel blends of B6 to B20 must
meet the requirements listed in the latest edition of

“ASTM D7467” (B6 to B20) and must be of an API
gravity of 30-45.

In North America biodiesel and biodiesel blends must
be purchased from the BQ-9000 accredited

producers and BQ-9000 certified distributors.

In other areas of the world, the use of biodiesel that is
BQ-9000 accredited and certified, or that is
accredited and certified by a comparable biodiesel

quality body to meet similar biodiesel quality
standards is required.

Engine Service Requirements with B20

Aggressive properties of biodiesel fuel may cause
debris in the fuel tank and fuel lines. The aggressive
properties of biodiesel will clean the fuel tank and fuel
lines. This cleaning of the fuel system can
prematurely block of the fuel filters. Perkins
recommends that after the initial usage of B20
biodiesel blended fuel the fuel filters must be

replaced at 50 hours.

52 M0080243-01

Maintenance Section
General Fuel Information

Glycerides present in biodiesel fuel will also cause
fuel filters to become blocked more quickly. Therefore
the regular service interval should be reduced to 250
hours.

When biodiesel fuel is used, crank case oil and
aftertreatment systems (if installed) may be

influenced. This influence is due to the chemical
composition and characteristics of biodiesel fuel,

such as density and volatility, and to chemical
contaminants that can be present in this fuel, such as
alkali and alkaline metals (sodium, potassium,
calcium, and magnesium).

• Crankcase oil fuel dilution can be higher when
biodiesel or biodiesel blends are used. This
increased level of fuel dilution when using
biodiesel or biodiesel blends is related to the
typically lower volatility of biodiesel. In cylinder
emissions control strategies utilized in many of the
industrial latest engine designs may lead to a
higher level of biodiesel concentration in the
engine oil pan. The long-term effect of biodiesel
concentration in crankcase oil is unknown.

• Perkins recommends the use of oil analysis to
check the quality of the engine oil if biodiesel fuel
is used. Ensure that the level of biodiesel in the
fuel is noted when the oil sample is taken.

Performance Related Issues with B20

Due to the lower energy content than the standard
distillate fuel B20 will cause a power loss in order 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 in fuel system deposits, most significant

of which are deposits within the fuel injector.

Perkins Diesel Fuel Cleaner T400012 is most
effective in cleaning and preventing the formation of

deposits. Refer to section, Perkins Diesel Fuel
System Cleaner for more information. Perkins Diesel
Fuel Conditioner U5MK8276 helps to limit deposit
issues by improving the stability of biodiesel while
also hindering the production of new deposits. For
more information refer to section, Perkins Diesel Fuel

Conditioner. Therefore the use of Perkins Diesel Fuel
Cleaner and or Perkins Diesel Fuel Conditioner is
recommended when running biodiesel blends,

especially B20.

Perkins T400012 Fuel Cleaner is most effective in
cleaning and preventing the formation of deposits.

Refer to “Perkins Diesel Fuel System Cleaner, and
Perkins” for more information. Perkins U5MK8276

Perkins Diesel Fuel Conditioner helps to limit deposit
issues by improving the stability of biodiesel while
also hindering the production of new deposits. For
more information refer to “Perkins Diesel Fuel

Conditioner, and Perkins”. Therefore the use of
Diesel Fuel Cleaner and or Diesel Fuel Conditioner is
recommended when running biodiesel blends,

especially B20.

General Requirements

Biodiesel has poor oxidation stability, which can
result in long-term problems in the storage of
biodiesel. Biodiesel fuel should be used within 6

months of manufacture. Equipment should not be
stored with the B20 biodiesel blends in the fuel

system for longer than 3 months.

Due to poor oxidation stability and other potential
issues, Perkins recommends that engines with
limited operational time either do not use biodiesel
blends or, while accepting some risk, limit biodiesel
blend to a maximum of B5. Examples of applications
that should limit the use of biodiesel are the following:
Standby generator sets and certain emergency
vehicles.

For standby generator sets and emergency vehicles
that cannot avoid use of biodiesel blends fuel quality
in the engine fuel tank must be sampled and checked
monthly. Test should include acid number
(EN14104), oxidation stability (EN 15751 commonly
know as the Rancimant test), and sediment
(ISO12937). For standby generator sets oxidation
stability of biodiesel blend must be 20 hours or more
as per EN 15751. If the test shows that the fuel has
degraded, fuel tank must be drained and engine
flashed by running with the fresh high-quality diesel
fuel.

For standby generator sets and emergency vehicles
that cannot avoid use of biodiesel blends fuel quality
in the engine fuel tank must be sampled and checked
monthly. Test should include acid number
(EN14104), oxidation stability (EN 15751 commonly
know as the Rancimant test), and sediment
(ISO12937). For standby generator sets oxidation
stability of biodiesel blend must be 20 hours or more
as per EN 15751. If the test shows that the fuel has
degraded, fuel tank must be drained and engine
flashed by running with fresh high-quality diesel fuel.

Perkins strongly recommends that seasonally
operated engines have the fuel systems, including
fuel tanks, flashed with conventional diesel fuel

before prolonged shutdown periods. An example of
an application that should seasonally flush the fuel
system is a combine harvester.

M0080243-01 53

Maintenance Section

General Fuel Information

Microbial contamination and growth can cause
corrosion in the fuel system and premature plugging
of the fuel filter. Consult your supplier of fuel for
assistance in selecting appropriate antimicrobial
additive.

Water accelerates microbial contamination and
growth. When biodiesel is compared to distillate

fuels, water is naturally more likely to exist in the
biodiesel. Frequent checks are therefore essential
and if necessary, drain the water separator.

Materials such as brass, bronze, copper, led, tin, and
zinc accelerate the oxidation process of the biodiesel
fuel. The oxidation process can cause deposits
formation therefore these materials must not be used

for fuel tanks and fuel lines.

Fuel for Cold-Weather Operation

The European standard “EN590” contains climate
dependant requirements and a range of options. The
options can be applied differently in each country.
There are five classes that are given to arctic
climates and severe winter climates. 0, 1, 2, 3 and 4.

Fuel that complies with “EN590” CLASS 4 can be
used at temperatures as low as −44 °C (−47.2 °F).
Refer to “EN590” fora detailed discretion of the

physical properties of the fuel.

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

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

In extreme cold ambient conditions, you may use the
aviation kerosene fuels that are specified in Group 2.
These fuels are intended to be used in temperatures
that can be as low as −54 °C (−65.2 °F). Refer to
Group 2 for detail and conditions of use of the
aviation kerosene fuels.

Aftermarket Fuel Additives

NOTICE

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

When auxiliary devices, accessories, or consum­ables (filters, additives) which are made by other
manufacturers are used on Perkins products, the
Perkins warranty is not affected simply because of
such use.

However, failures that result from the installation
or use of other manufacturers devices, accesso­ries, or consumables are NOT Perkins defects.
Therefore, the defects are NOT covered under the
Perkins warranty.

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

potential damage to the fuel system or the engine.

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

Note: For the best results, your fuel supplier should
treat the fuel when additives are required. The
treated fuel must meet the requirements that are
stated in table 13 .

Perkins Diesel Fuel System Cleaner

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

Perkins Diesel Fuel Cleaner (part number T400012)
is the only fuel cleaner that is recommended by
Perkins.

Mixing alcohol or gasoline with diesel fuel can
produce an explosive mixture in the engine
crankcase or the fuel tank. Alcohol or gasoline
must not be used in order to dilute diesel fuel.

Failure to follow this instruction may result in
death or personal injury.

There are many other diesel fuel specifications that
are published by governments and by technological
societies. Usually, those specifications do not review
all the requirements that are addressed in table 13 .
To ensure optimum engine performance, a complete
fuel analysis should be obtained before engine
operation. The fuel analysis should include all the
properties that are stated in the table 13 .

If biodiesel or biodiesel blends of fuel are to be used,
Perkins require the use of Perkins fuel cleaner. For

more information on the use of biodiesel and
biodiesel blends refer to “Biodiesel Fuel”.

Perkins fuel cleaner will remove deposits that can
form in the fuel system with the use of biodiesel and
biodiesel blends. These deposits can create a loss of
power and engine performance.

Once the fuel cleaner has been added to the fuel, the
deposits within the fuel system are removed after 30

hours of engine operation. For maximum results,
continue to use the fuel cleaner for up to 80 hours.
Perkins fuel cleaner can be used on an on-going
basis with no adverse impact on engine or fuel
system durability.

Detailed instructions on the rate of which the fuel
cleaner must be use are on the container.

54 M0080243-01

Maintenance Section
General Fuel Information

Perkins Diesel Fuel Conditioner

Perkins Diesel Fuel Conditioner (part number
U5MK8276) can be used in these engine models.
The diesel fuel conditioner is a proprietary metal and
ash free formulation that has been extensively tested
for use with distillate diesel fuels for use in Perkins

diesel engines. The diesel fuel conditioner helps
address many of the challenges that various fuels
worldwide present with regard to fuel life/stability,
engine startability, injector deposits, fuel system life,
and long-term engine performance. Contact a
Perkins distributor for more information.

Note: Diesel fuel additives/conditioners may not
improve markedly poor diesel fuel properties enough
to make poor diesel acceptable for use.

Diesel fuel conditioner is a proven high performance,
multipurpose diesel fuel conditioner that is designed
to improve:

• Fuel economy (through fuel system clean-up)

• Lubricity

• Oxidation stability

• Detergency/dispersancy

• Moisture dispersancy

• Corrosion protection

• Cetane (typically 2-3 cetane numbers)

The diesel fuel conditioner also reduces the
formation of gums, resins, and sludge, and disperses

insoluble gums.

For maximum overall benefits, ask your fuel supplier
to add the fuel conditioner at the recommended treat

rate before fuel delivery. Or you may add the fuel
conditioner at the recommended treat rate during the
early weeks of fuel storage.

Contamination Control
Recommendations for Fuels

Fuels of “ISO 18/16/13” cleanliness level or cleaner
as dispensed into the engine or application fuel tank

should be used. This standard of will reduce risk of
power loss, fuel system failures, and related down

time of engines. This cleanliness level is important for
unit injector fuel system. The fuel system utilizes
higher fuel injection pressures and have tight
clearances between moving parts to meet required
stringent emissions regulations. As a result, particle
contaminants as small as 4 µm can cause scoring
and scratching of internal pump and injector surfaces
and of injector nozzles.

Water in the fuel causes cavitation, corrosion of fuel
system parts, and provides an environment where

microbial growth in the fuel can flourish. Other
sources of fuel contamination are soaps, gels, or
other compounds that may result from undesirable
chemical interactions in the fuels, particularly in
ULSD. Gels and other compounds can also form in
biodiesel fuel at low temperatures or if biodiesel is
stored for extended periods. The best indication of
microbial contamination, fuel additives, or cold

temperature gel is rapid filter plugging of bulk fuel
filters or application fuel filters.

To reduce downtime due to contamination, follow
these fuel maintenance guidelines.

• Use high-quality fuels per recommended and
required specifications

• Fill fuel tanks with fuels of “ISO 18/16/13”
cleanliness level or cleaner, in particular for
engines with common rail and unit injection
systems. When you refuel the tank, filter the fuel
through a 4 µm absolute filter (Beta 4 = 75 up to

200) in order to reach the recommended
cleanliness level. This filtration should be located
at the device that dispenses the fuel to the fuel
tank. In addition, filtration at the dispensing point
should remove water to ensure that fuel is
dispensed at 500 ppm water or less.

• Perkins recommends the use of bulk fuel filter /
coalescer units which clean the fuel of both
particulate contamination and water in a single
pass.

• Ensure that you use Perkins Advanced Efficiency
Fuel Filters. Change your fuel filters per
recommended service requirements or as needed.

• Drain your water separators daily.

• Drain your fuel tanks of sediment and water per
the Operation and Maintenance Manual
instructions.

• Install and maintain a properly designed bulk filter
/ coalescer filtration system. Continuous bulk
filtration systems may be required to ensure that
dispensed fuel meets the cleanliness target.
Consult your Perkins distributor for availability of
bulk filtration products.

• Centrifugal filters may need to be used as a pre­filter with fuel that is severely contaminated with
gross amounts of water and/or large particulate
contaminants. Centrifugal filters can effectively
remove large contaminants. Centrifugal filters may
not be able to remove the small abrasive particles
required to achieve the recommended “ISO”
cleanliness level. Bulk filter / coalescers are
necessary as a final filter to achieve the
recommended cleanliness level.

M0080243-01

• Install desiccant type breathers of 4 µm or less
absolute efficiency with the ability to remove water
on bulk storage tanks.

• Follow proper practices of fuel transportation.
Filtration from the storage tank to the application
promotes the delivery of clean fuel. Fuel filtration
can be installed at each transport stage to keep
the fuel clean.

• Cover, protect, and ensure cleanliness of all
connection hoses, fittings, and dispensing
nozzles.

Consult your local Perkins distributor for additional
information on Perkins designed and produced
filtration products.

Renewable and Alternative Fuels

Perkins supports development and use of renewable
fuels through sustainability initiatives. In recent years
various forms of renewable and alternative

(synthetic) diesel fuels have started to emerge.

55

Maintenance Section

General Fuel Information

Synthetic diesel fuels are produced by gasification of
various feedstock and then synthesis to liquid to
obtain paraffinic diesel fuel. Based on the feedstock
used these fuels are commonly referred to as
Biomass to liquid (BTL), Gas to liquid (GTL) and Coal
to liquid (CTL). Hydrotreating of vegetable oils and
animal fats is another emerging process for
production of bio based diesel fuel called
Hydrotreated Vegetable Oil (HVO).

BTL and HVO fuels are considered to be low carbon
fuels as they reduce carbon foot print compared to

fossil fuels and are commonly referred to as
renewable fuels. These fuels must not be confused

with biodiesel FAME which is fundamentally different
fuel and is discussed in a separate section in this
manual.

These paraffinic fuels have virtually no sulphur or
aromatics and have very high cetane numbers which
enable very clean burning and efficient engine
operation. Chemically these fuels are similar to diesel
fuel derived from petroleum and are therefore
suitable to use in diesel engines as a replacement or
blend stock with conventional diesel fuel. To be

acceptable renewable and alternative fuels must
meet latest edition of the paraffinic diesel fuel
specification “CENTS 15940”. The fuel should also
meet requirements described in table 13 , Perkins
Specification for Distillate Diesel Fuel, EN590, or
latest ASTM D975 specification.

Ensure that the fuel has got appropriate cold flow
properties (cloud point and CFPP) for the minimum
statistical ambient temperature the engine is
expected to see in the operation. The Fuel must also
meet lubricity requirements as specified in the
lubricity section of this “Operation and Maintenance
Manual” Fluid Recommendations

56 M0080243-01

Maintenance Section
Maintenance Recommendations

Maintenance
Recommendations

i02909163

System Pressure Release

SMCS Code: 1250; 1300; 1350; 5050

Coolant System

Pressurized system: Hot coolant can cause seri­ous burn. To open cap, stop engine, wait until ra­diator is cool. Then loosen cap slowly to relieve
the pressure.

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

Fuel System

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

High Pressure Fuel Lines (If Equipped)

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

Engine Oil

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

i06221218

Welding on Engines with
Electronic Controls

SMCS Code: 1000

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.

Correct 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.

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.

• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system.

Before any service or repair is performed on the
engine fuel lines, perform the following tasks:

1. Stop the engine.

2. Wait for ten minutes.

Do not ground the welder to electrical components

NOTICE

such as the ECM or sensors. Improper grounding
can cause damage to the drive train bearings, hy­draulic components, electrical components, and oth-

er components.

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

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

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

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

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

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

M0080243-01

57

Maintenance Section

Severe Service Application

• Electronic components for the driven
equipment

• ECM

• Sensors

• Electric operated fuel pump

• Electronically controlled valves

• Relays

NOTICE

Do not use electrical components (ECM or ECM sen­sors) or electronic component grounding points for
grounding the welder.

5. Connect the welding ground cable directly to the
part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to the
following components. Bearings, hydraulic
components, electrical components, and ground
straps.

Note: If electrical/electronic components are used as
a ground for the welder or are located between the
welder ground and the weld, current flow from the
welder could severely damage the component.

6. Protect the wiring harness from welding debris and
spatter.

7. Use standard welding practices to weld the
materials.

i06221219

Severe Service Application

SMCS Code: 1000

Severe service is the application of an engine that
exceeds the current published standards for that
engine. Perkins maintains standards for the following
engine parameters:

Illustration 29 g01075639

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

(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery 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 and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder

• Performance such as power range, speed range,
and fuel consumption

• Fuel quality

• Operational Altitude

• Maintenance intervals

• Oil selection and maintenance

• Coolant type and maintenance

• Environmental qualities

• Installation

• The temperature of the fluid in the engine

Refer to the standards for the engine or consult a
Perkins dealer or distributor to determine if the

engine is operating within the defined parameters.

Severe service operation can accelerate component
wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention of
full service life.

Due to individual applications, identification of all of
the factors which can contribute to severe service

operation is impossible. Consult a Perkins dealer or
distributor for the unique maintenance that is
necessary for the engine.

58 M0080243-01

Maintenance Section
Severe Service Application

The operating environment, incorrect operating
procedures, and incorrect maintenance procedures
can be factors which contribute to a severe service

application.

Environmental Factors

Ambient temperatures – The engine may be

exposed to extended operation in extremely cold or
hot environments. Valve components can be
damaged by carbon buildup if the engine is
frequently started and stopped in very cold
temperatures. Extremely hot intake air reduces
engine performance.

Quality of the air – The engine may be exposed to
extended operation in an environment that is dirty or
dusty, unless the equipment is cleaned regularly.
Mud, dirt, and dust can encase components.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals.

Buildup – Compounds, elements, corrosive
chemicals, and salt can damage some components.

Altitude – Problems can arise when the engine is
operated at altitudes that are higher than the
intended settings for that application. Necessary
adjustments should be made.

Incorrect Operating Procedures

• Extended operation at low idle

• Frequent hot shutdowns

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application

Incorrect Maintenance Procedures

• Extending the maintenance intervals

• Failure to use recommended fuel, lubricants, and
coolant/antifreeze

M0080243-01 59

Maintenance Section

Maintenance Interval Schedule

i07124141

Maintenance Interval Schedule

SMCS Code: 1000; 4450; 7500

When Required

“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . . 60

“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 61

“ Battery or Battery Cable - Disconnect” . . . . . . . . . 62

“ Engine Air Cleaner Element (Dual Element) -

Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 69

“ Engine Air Cleaner Element (Single Element) -

Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 71

“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . . 77

“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 81

“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Daily

“ Air Tank Moisture and Sediment - Drain” . . . . . . . 60

“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 66

“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . . 68

“ Cooling System Supplemental Coolant Additive

(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

“ Fuel System Primary Filter (Water Separator)

Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 78

“ Fuel System Secondary Filter - Replace”. . . . . . . 80

“Grounding Stud - Inspect/Clean/Tighten” . . . . . . . 81

“ Hoses and Clamps - Inspect/Replace”. . . . . . . . . 82

“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 84

“ Water Pump - Inspect” . . . . . . . . . . . . . . . . . . . . . . 85

Every 2500 Service Hours

“ Coolant Temperature Regulator - Replace” . . . . . 66

“ Electronic Unit Injector - Check/Replace” . . . . . . 68

“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 72

“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . 76

“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . . 76

Every 3000 Service Hours or 2
Years

“ Coolant (DEAC) - Change” . . . . . . . . . . . . . . . . . . 63

“ Engine Air Cleaner Service Indicator - Inspect” . . 72

“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 72

“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 81

“ Fuel System Primary Filter/Water Separator -

Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

“ Power Take-Off Clutch - Check” . . . . . . . . . . . . . . 83

“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 84

Every 500 Service Hours

“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 62

“ Engine Air Cleaner Element (Dual Element) -

Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 69

“ Engine Air Cleaner Element (Single Element) -

Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 71

“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 73

“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . 74

Every 500 Service Hours or 1 Year

Every 4000 Service Hours

“ Air Compressor - Check”. . . . . . . . . . . . . . . . . . . . 60

Every 6000 Service Hours or 3
Years

“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . . 66

Every 585,000 L (154,540 US gal) of
Fuel

“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . . 83

Every 12 000 Service Hours or 6
Years

“ Coolant (ELC) - Change”. . . . . . . . . . . . . . . . . . . . 64

“ Battery Electrolyte Level - Check” . . . . . . . . . . . . 61

60 M0080243-01

Maintenance Section
Air Compressor - Check

i06223534

Air Compressor - Check

(If Equipped)

SMCS Code: 1803-535

Do not disconnect the air line from the air com­pressor governor without purging the air brake

and the auxiliary air systems. Failure to purge the
air brake and the auxiliary air systems before re­moving the air compressor and/or the air lines
could cause personal injury.

The pressure relief valve for the air compressor
releases air at 1723 kPa (250 psi). If the pressure
relief valve for the air compressor exhausts, all
personnel should be at a safe distance away from the
air compressor. All personnel should also stay clear
of the air compressor when the engine is operating
and the air compressor is exposed.

Consult your Perkins distributor for assistance.

i00847451

Air Tank Moisture and
Sediment - Drain

(If Equipped)

SMCS Code: 1466-543-M&S

Moisture and sediment in the air starting system can
cause the following conditions:

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

Illustration 30 g03813903

Typical example

(1) Pressure relief valve

If the air compressor pressure relief valve that is
mounted in the air compressor cylinder head is
bypassing compressed air, there is a malfunction
in the air system, possibly ice blockage. Under
these conditions, your engine may have insuffi­cient air for normal brake operation.

Do not operate the engine until the reason for the
air bypass is identified and corrected. Failure to
heed this warning could lead to property damage,
personal injury, or death to the operator or
bystanders.

The function of the pressure relief valve is to bypass
air when there is a malfunction in the system for the
air compressor.

When opening the drain valve, wear protective
gloves, a protective face shield, protective cloth­ing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal
injury.

1. Open the drain valve that is on the bottom of the

air tank. Allow the moisture and sediment to drain.

2. Close the drain valve.

3. Check the air supply pressure. The air starting

motor requires a minimum of 620 kPa (90 psi) of
air pressure to operate properly. The maximum air
pressure must not exceed 1550 kPa (225 psi).
The normal air pressure will be 758 to 965 kPa
(110 to 140 psi).

i02039199

Battery - Recycle

SMCS Code: 1401-005; 1401-535; 1401-561; 1401;

1401-510

Always recycle a battery. Never discard a battery.
Return used batteries to one of the following
locations:

• A battery supplier

• An authorized battery collection facility

M0080243-01 61

Maintenance Section

Battery - Replace

• A recycling facility

i01878164

Battery - Replace

SMCS Code: 1401-510

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

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

serviced.

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

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

1. Switch the engine to the OFF position. Remove all

electrical loads.

2. Turn off any battery chargers. Disconnect any
battery chargers.

3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the NEGATIVE “-” terminal

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

4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the POSITIVE “+” terminal

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

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

8. Connect the cable from the NEGATIVE “-” terminal
on the starter motor to the NEGATIVE “-” battery
terminal.

i02747977

Battery Electrolyte Level ­Check

SMCS Code: 1401-535-FLV

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

All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a

face shield and protective clothing when working
on or near batteries.

1. Remove the filler caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

If the addition of water is necessary, use distilled
water. If distilled water is not available use clean

water that is low in minerals. Do not use artificially
softened water.

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

3. Install the caps.

4. Keep the batteries clean.

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

• Use a solution of 0.1 kg (0.2 lb) baking soda
and 1 L (1 qt) of clean water.

• Use a solution of ammonium hydroxide.

Thoroughly rinse the battery case with clean
water.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure that

the engine start switch is OFF.

7. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.

62 M0080243-01

Maintenance Section
Battery or Battery Cable - Disconnect

i06221249

Battery or Battery Cable ­Disconnect

SMCS Code: 1401; 1402-029

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

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
four 12 V batteries are involved, 2 negative
connections must be disconnected.

i06934547

Belts - Inspect/Adjust/Replace

SMCS Code: 1357-510; 1357-025; 1357-040

3. Remove the positive connection.

4. Clean all disconnected connection and battery

terminals.

5. Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to fit incorrectly.
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 connect the battery, connect the

positive connection before the negative connector.

Illustration 31 g06046748

Typical example

(1) Belt
(2) Square drive
(3) Tensioner

Inspect

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

• Inspect the belt for cracks, splits, glazing, grease,
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.

M0080243-01 63

Maintenance Section

Coolant (DEAC) - Change

• More than one section of the belt is displaced in
one rib of a maximum length of 50.8 mm (2 inch)

Adjust

The engine is equipped with an automatic belt
tensioner (3). Manual adjustment of the belt is not
required.

Replace

The tensioner (3) has a square drive (2) that can be
used to remove the tension from the belt, allowing the
belt to be removed. For a full description on replacing
the belt refer to Disassembly and Assembly,
Alternator Belt - Remove and Install.

i06221395

Coolant (DEAC) - Change

SMCS Code: 1350-070; 1395-044

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

• The engine overheats frequently.

• Foaming 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: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained.

Illustration 32 g02351659

Typical example of a cooling system drain valve. The
valve is towards the bottom of the radiator.

Drain

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

pressure.

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

Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.

2. Open the cooling system drain valve.

Allow the coolant to drain.

Flush

1. Flush the cooling system with clean water and a

suitable cleaning agent in order to remove any
debris. Refer to your Perkins distributor for
suitable cleaning agents.

2. Close the cooling system drain valve.

64 M0080243-01

Maintenance Section
Coolant (ELC) - Change

Do not fill the cooling system faster than 5 L

NOTICE

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

Cooling system air locks may result in engine
damage.

3. Fill the cooling system with clean water and install
the cooling system filler cap.

4. Start and run the engine until normal operating
temperature.

5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valve. Allow the water to drain. Flush the cooling
system with clean water.

6. Close the cooling system drain valve.

Fill

NOTICE

Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

1. Fill the cooling system with coolant/antifreeze.
Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” topic for more
information on cooling system specifications. Do
not install the cooling system filler cap.

5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.

i06221440

Coolant (ELC) - Change

SMCS Code: 1350-070; 1395-044

NOTICE

Perkins ELC must be using with an extender in order
to achieve 12000 hours operation. For more informa­tion on a suitable extender contact your Perkins
distributor.

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

• The engine overheats frequently.

• Foaming 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
temperature regulator after the cooling system has
been drained.

2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at high
idle for 1 minute in order to purge the air from the
cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass.

4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap is
damaged, discard the old filler cap and install a
new filler cap. If the gasket that is on the cooling
system filler cap is not damaged, perform a
pressure test. The correct pressure for the cooling
system filler cap is stamped on the face of the
cooling system filler cap. If the cooling system filler
cap does not retain the correct pressure, install a
new cooling system filler cap.

M0080243-01 65

Maintenance Section

Coolant (ELC) - Change

Illustration 33 g02351659

Typical example

Fill the cooling system no faster than 19 L (5 US gal)

NOTICE

per minute to avoid air locks.

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

4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve. Allow the
water to drain. Flush the cooling system with clean
water. Close the drain valve.

Fill

NOTICE

Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to this Operation and Maintenance
Manual, “Fluid Recommendations” for more
information on cooling system specifications. Do
not install the cooling system filler cap.

Drain

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

pressure.

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

Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.

2. Open the cooling system drain valve.

Allow the coolant to drain.

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

2. Close the drain valve.

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

engine rpm to high idle. Run the engine at high
idle for 1 minute in order to purge the air from the
cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass.

4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. Only
install the used filler cap if the gasket is not
damaged. Test the cap for the correct pressure.
The correct pressure for the cooling system filler
cap is stamped on the face of the cooling system
filler cap. If the cooling system filler cap does not
retain the correct pressure, install a new cooling
system filler cap.

66 M0080243-01

Maintenance Section
Coolant Extender (ELC) - Add

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

i05197396

Coolant Extender (ELC) - Add

SMCS Code: 1352-544-NL

In order for Perkins ELC to achieve 12000 hours an
extender must be added at 6000 hours. For a
suitable extender, contact your Perkins dealer or

Perkins distributor.

i03842450

Coolant Level - Check

SMCS Code: 1395-082

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

Illustration 34 g00285520

Cooling system filler cap

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 within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.

Illustration 35 g00103639

Typical filler cap gaskets

3. Clean the cooling system filler cap and check the
condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i06223869

Coolant Temperature
Regulator - Replace

SMCS Code: 1355-510

Replace the water temperature regulator before the
water temperature regulator fails. Replacing the
water temperature regulator reduces the chances for
unscheduled downtime.

A water temperature regulator that fails in a partially
opened position can cause overheating or
overcooling of the engine.

A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear of
the cylinder liner.

A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.

M0080243-01 67

Maintenance Section

Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Failure to replace the water temperature regulator on

NOTICE

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 regulator installed.

If the water temperature regulator is installed incor­rectly, the engine may overheat, causing cylinder
head damage. Ensure that the new water tempera­ture regulator is installed in the original position. En­sure that the water temperature regulator vent hole is

open.

Do not use liquid gasket material on the gasket or cyl­inder head surface.

NOTICE
Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte-

nance, 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.

Note: If replacing only the water temperature
regulator, only drain the coolant to a level that is
below the water temperature regulator housing.

Test for SCA Concentration

Heavy-Duty Coolant/Antifreeze and SCA

NOTICE

Do not exceed the recommended six percent supple­mental coolant additive concentration.

Use a Coolant Conditioner Test Kit in order to check
the concentration of the SCA.

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.

Refer to Disassembly and Assembly, “Water
Temperature Regulator - Remove and Install” for the
replacement procedure.

i03644948

Cooling System Supplemental
Coolant Additive (SCA) - Test/
Add

SMCS Code: 1352-045; 1395-081

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.

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.

NOTICE

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

1. Slowly loosen the cooling system filler cap in order
to relieve the pressure. Remove the cooling
system filler cap.

Note: Always discard drained fluids according to
local regulations.

2. If necessary, drain some coolant from the cooling
system into a suitable container in order to allow
space for the extra SCA.

68 M0080243-01

Maintenance Section
Driven Equipment - Check

3. Add the correct amount of SCA. Refer to the
Operation and Maintenance Manual, “Refill
Capacities and Recommendations” for more
information on SCA requirements.

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

i02151646

Driven Equipment - Check

SMCS Code: 3279-535

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

• Inspection

• Adjustment

The operation of a Perkins engine with an electronic
unit injector which is improperly adjusted may reduce
engine efficiency. This reduced efficiency may result
in excessive fuel usage and/or shortened engine
component life.

Note: Only qualified service personnel should
perform this maintenance.

Refer to the Systems Operation, Testing and
Adjusting, “Electronic Unit Injector - Test” for the test
procedure. Refer to Systems Operation, Testing and
Adjusting, “Electronic Unit Injector - Adjust” for the
adjustment procedure.

Refer to Disassembly and Assembly, “Electronic Unit
Injector - Remove” and Disassembly and Assembly,
“Electronic Unit Injector - Remove” for the removal
and installation of an injector.

NOTICE

The camshafts must be correctly timed with the
crankshaft before an adjustment of the lash for the
fuel injector is made. The timing pins must be re­moved from the camshafts before the crankshaft is

turned or damage to the cylinder block will be the
result.

• Lubrication

• Other maintenance recommendations

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

i06225020

Electronic Unit Injector ­Check/Replace

SMCS Code: 1251-510; 1251-535; 1290-535; 1290-

510

Be sure the engine cannot be started while this
maintenance is being performed. To prevent pos­sible injury, do not use the starting motor to turn
the flywheel.

Hot engine components can cause burns. Allow
additional time for the engine to cool before
measuring/adjusting the unit injectors.

The electronic unit injectors use high voltage.
Disconnect the unit injector enable circuit con­nector in order to prevent personal injury. Do not
come in contact with the injector terminals while
the engine is running.

i06733463

Engine - Clean

SMCS Code: 1000-070

Personal injury or death can result from high
voltage.

Moisture can create paths of electrical
conductivity.

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

NOTICE

Accumulated grease and oil on an engine is a fire
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

M0080243-01 69

Maintenance Section

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

Note: Caution must be used 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
to wash the engine.

Ensure that care is taken that the safety labels,
emission label, and all other information labels are

not removed during engine cleaning.

i05207494

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

SMCS Code: 1051; 1054-040; 1054-070; 1054-510

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.

Replace the dirty air cleaner elements with clean air
cleaner elements. Before installation, the air cleaner

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

Dual Element Air Cleaners

The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner
element.

The primary air cleaner element can be used up to
six times if the element is properly cleaned and
properly inspected. The primary air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.

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

to replace the secondary air cleaner element.

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

Never service the air cleaner element with the engine

NOTICE

running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

Note: The air filter system may not have been

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

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

• Check the precleaner (if equipped) and the dust
bowl daily for accumulation of dirt and debris.
Remove any dirt and debris, as needed.

• Operating in dirty conditions may require more
frequent service of the air cleaner element.

• The air cleaner element should be replaced at
least one time per year. This replacement should
be performed regardless of the number of
cleanings.

Illustration 36 g00736431

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

1. Remove the cover. Remove the primary air cleaner
element.

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

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

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

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

70 M0080243-01

Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

5. Remove the tape from the air inlet. Install the
secondary air cleaner element. Install a primary air
cleaner element that is new or cleaned.

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.

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) pres­surized air or vacuum cleaning to clean the primary
air cleaner element.

Pressurized Air

Personal injury can result from air pressure.

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

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

Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more

than three times. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi). Pressurized air will not
remove deposits of carbon and oil.

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.

Refer to the OEM information in order to determine
the number of times that the primary air cleaner

element can be cleaned. Do not clean the primary air
filter element more than three times. The primary air
cleaner element must be replaced at least one time

per year.

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

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

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

• pressurized air

• Vacuum cleaning

Illustration 37 g00281692

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”.

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.

M0080243-01 71

Maintenance Section

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

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

Inspecting the Primary Air Cleaner
Elements

Illustration 38 g00281693

Inspect the clean, dry primary air cleaner element.
Use a 60 W blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears and/
or holes. Inspect the primary air cleaner element for
light that may show through the filter material. If it is
necessary in order to confirm the result, compare the
primary air cleaner element to a new primary air
cleaner element that has the same part number.

Do not use a primary air cleaner element that has
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
pleats, gaskets, or seals. Discard damaged primary
air cleaner elements.

i04150572

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

SMCS Code: 1051; 1054-070; 1054-040; 1054-510

Perform the Operation and Maintenance Manual,
“Engine Air Cleaner Service Indicator-Inspect”
procedure and perform the Operation and
Maintenance Manual, “Engine Air Precleaner Check/
Clean” procedure (if equipped) before performing the
following procedure.

Never run the engine without an air cleaner element

NOTICE

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.

NOTICE

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

Illustration 39 g00310664

(1) Air cleaner cover
(2) Air filter element
(3) Air inlet

1. Remove air cleaner cover (1) and remove air filter
element (2).

2. Cover air inlet (3) with tape or a clean cloth so that
debris cannot enter the air inlet.

3. Clean the inside of air cleaner cover (1). Clean the
body that holds the air cleaner element.

4. Inspect the replacement element for the following
items:damage, dirt and debris.

5. Remove the seal from the opening of the air inlet.

6. Install a clean, undamaged air filter element (2).

7. Install air cleaner cover (1).

8. Reset the air cleaner service indicator.

72 M0080243-01

Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

i06221262

Engine Air Cleaner Service
Indicator - Inspect

(If Equipped)

SMCS Code: 7452-040

Some engines may be equipped with a different
service indicator.

Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before and after the air cleaner

element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service

the air cleaner service indicator.

The service indicator may be mounted on the clean
side of the air cleaner housing or in a remote
location.

If the service indicator does not reset easily, or if the
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 plugged.

If necessary, replace the service indicator more
frequently in environments that are severely dusty.
Replace the service indicator annually regardless of
the operating conditions. Replace the service
indicator when the engine is overhauled, and
whenever major engine components are replaced.

Note: When a new service indicator is installed,
excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque of
2 N·m (18 lb in).

i02323089

Engine Mounts - Inspect

SMCS Code: 1152-040; 1152

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.

Illustration 40 g00103777

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.

Test the Service Indicator

Service indicators are important instruments.

• Check for ease of resetting. The service indicator
should reset in less than three pushes.

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.

i06934495

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

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

• Check the movement of the service indicator core
when the engine is run at full load speed. The core
should latch approximately at the greatest vacuum
that is attained.

M0080243-01 73

Maintenance Section

Engine Oil Sample - Obtain

Illustration 41 g06174074

Typical installation of the oil level gauge

(1) Oil filler cap
(2) Oil level gauge

Engine damage can occur if the crankcase is filled

NOTICE

above the “FULL” mark on the oil level gauge
(dipstick).

An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel­oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re­duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers and excessive oil consumption.

Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De­posits in the combustion chamber lead to the follow­ing problems: guttering of the valves, packing of
carbon under the piston rings and wear of the cylin­der liner.

If the oil level is above the “FULL” mark on the oil lev­el gauge, drain some of the oil immediately.

1. Remove the oil filler cap and check the oil level.

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

Illustration 42 g00110310

Partial view of the oil level gauge

(Y) “ADD” mark
(X) “FULL” mark

NOTICE

Perform this maintenance with the engine stopped.

2. To choose the correct type of oil for this engine,
refer to this Operation and Maintenance Manual,
“Fluid Recommendations”.

3. Clean the oil filler cap. Install the oil filler cap.

4. Record the amount of oil that is added. For the

next oil sample and analysis, include the total
amount of oil that has been added since the
previous sample. Recording this information helps
to provide the most accurate oil analysis.

i01907674

Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM

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

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

74 M0080243-01

Maintenance Section
Engine Oil and Filter - Change

Obtain the Sample and the
Analysis

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

In order to help obtain the most accurate analysis,
record the following information before an oil sample
is taken:

• The date of the sample

• Engine model

• Engine number

• Service hours on the engine

• The number of hours that have accumulated since
the last oil change

• The amount of oil that has been added since the
last oil change

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

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

sample.

To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.

The sample can be checked for the following: the
quality of the oil, the existence of any coolant in the
oil, the existence of any ferrous metal particles in the
oil and the existence of any nonferrous metal
particles in the oil.

Care must be taken to ensure that fluids are con-

NOTICE

tained 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.

Contaminants may cause rapid wear and shortened
component life.

Oil and Filter Change Intervals

The standard engine oil and filter change period is
500 hours. There are several other factors that can

alter the standard engine oil and filter change of 500
hours.

• If the engine is using engine oil analysis to
determine oil and filter change period.

• The engine is working in a severe service
environment/Load Factor

• Infrequent operation of the engine

Refer to this Operation and Maintenance Manual,
Severe Service Application for more information on
reducing the engine oil and filter change period. For
severe service applications the recommended oil and
filter change period is 250 hours.

If the engine is operated in severe service conditions,
Perkins recommends the use of engine oil sampling.
Refer to this Operation and Maintenance Manual,
Engine Oil sample - Obtain for more information.

i07124142

Engine Oil and Filter - Change

SMCS Code: 1318-510

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

If the engine is operated infrequently less than 500
hours in a 12-month period, then the engine oil and
filter change should be conducted yearly.

Drain the Engine Lubricating Oil

Do not drain the engine lubricating oil when the
engine is cold. As the engine lubricating oil cools,
suspended waste particles settle on the bottom of the
oil pan. The waste particles are not removed with
draining cold oil. Drain the oil pan with the engine
stopped. Drain the oil pan with the oil warm. This
draining method allows the waste particles that are
suspended in the oil to be drained properly.

Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.

M0080243-01

Note: Ensure that the vessel that will be used is large
enough to collect the waste oil.

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

• If the engine is equipped with a drain valve, turn
the drain valve knob counterclockwise to drain the
oil. After the oil has drained, turn the drain valve
knob clockwise to close the drain valve.

• If the engine is not equipped with a drain valve,
remove the oil drain plug to allow the oil to drain.

After the oil has drained, the oil drain plug should be
cleaned. If necessary, replace the O ring seal and
install the plug. Tighten the drain plug to 35 N·m
(26 lb ft).

Replace the Oil Filter

75

Maintenance Section

Engine Oil and Filter - Change

Note: Engine oil filter can be on engine or connected
remotely. The engine oil filter in this section is the
remote type of instillation. The basic removing and
installing procedures can be applied to both types of
oil filter installation

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, and crankshaft. As a result of the larg­er waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recom­mended by Perkins.

1. Ensure that the oil filter and the area around the oil
filter is clean before removal. Remove the oil filter
with a suitable tool.

Illustration 43 g06174433

(A) Connections for the remote oil filter

2. Clean sealing surface (1).

3. Apply clean engine oil to O ring seal (2) for the new

oil filter (3).

NOTICE

Do not fill the oil filter with oil before installing. This oil
would not be filtered and could be contaminated.

Contaminated oil can cause accelerated wear to en­gine components.

4. Install the new oil filter (3). Spin on the oil filter until
the O ring (2) contacts the sealing surface (1).
Then rotate the oil filter 1 full turn. Remove the
container and disposal of the waste oil in
accordance with local regulations.

Fill the Oil Pan

1. Remove the oil filler cap. Refer to this Operation

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

76 M0080243-01

Maintenance Section
Engine Valve Lash - Check

2. Start the engine and run the engine at LOW IDLE
for 2 minutes. Perform this procedure 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.

4. .Remove the oil level gauge to check the oil level.
Maintain the oil level between the ADD and FULL
marks on the side of the oil level gauge.

i07014235

Engine Valve Lash - Check

SMCS Code: 1105-535

Ensure that the engine cannot be started while
this maintenance is being performed. To help pre­vent possible injury, do not use the starting motor
to turn the flywheel.

Hot engine components can cause burns. Allow
additional time for the engine to cool before
measuring/adjusting valve lash clearance.

NOTICE

Only qualified service personel should perform this
maintenance. Refer to the Service Manual or your au­thorized Perkins dealer or your Perkins distributor for
the complete valve lash adjustment procedure.

Operation of Perkins engines with incorrect valve
lash can reduce engine efficiency, and also reduce
engine component life.

The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended only on engine ratings 330 kW
(442 hp) and greater. The adjustment is necessary
due to the initial wear of the valve train components
and to the seating of the valve train components.

This maintenance is recommended as part of a
lubrication and preventive maintenance schedule to
help provide maximum engine life. For engine ratings
less than 330 kW (442 hp), the initial valve lash
adjustment is not necessary.

Note: All engine ratings must have the engine valve
lash performed at 2500 hours.

Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement,

allow the valves to cool before this maintenance is
performed.

During valve adjustment, visibly inspect the valve
train of wear or damage.

Refer to Systems Operation, Testing and Adjusting,
“Engine Valve Lash - Inspect/Adjust” for more
information.

i06891886

Engine Valve Rotators ­Inspect

SMCS Code: 1109-040

NOTICE

A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and

shorten valve life. If a damaged rotator is not re­placed, valve face guttering could result and cause
pieces of the valve to fall into the cylinder. This can
cause piston and cylinder head damage.

Note: Use of a platform may be necessary to reach
the engine valve rotators.

Perform this procedure after the valve lash has been
set.

Note: Ensure that the engine cannot be started
except by the person performing the maintenance
procedure. Install a “DO NOT OPERATE” tag near
the starting mechanism.

1. Remove the covers for the valve mechanisms.
Refer to the Disassembly and Assembly Manual,
“Valve Cover - Remove and Install” for the
procedure.

2. Mark the tops of the valve rotators with a
permanent marker. Note the position of the marks.

3. Install the covers for the valve mechanisms. Refer
to the Disassembly and Assembly Manual, “Valve
Cover - Remove and Install” for the procedure.

4. Start the engine. Operate the engine for 5 minutes.
Stop the engine.

5. Remove the covers for the valve mechanisms.
Refer to the Disassembly and Assembly Manual,
“Valve Cover - Remove and Install” for the
procedure.

6. Observe the position of the marks that are on the
valve rotators.

7. If any valve fails to rotate, consult your Perkins
distributor.

8. Install the covers for the valve mechanisms. Refer
to the Disassembly and Assembly Manual, “Valve
Cover - Remove and Install” for the procedure.

M0080243-01

77

Maintenance Section

Fuel System - Prime

i06933198

Fuel System - Prime

(General Instructions)

SMCS Code: 1250-548; 1258-548

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

Refer to this Operation and Maintenance Manual,
“General Hazard Information” before any
adjustments or repairs are performed

If necessary, perform minor adjustments. Repair any
leaks from the fuel system and from the cooling,
lubrication, or air systems. Ensure that all
adjustments and repairs are performed by authorized
personnel that have had the correct training.

The fuel system should be primed under the following
conditions:

Priming Fuel Pumps

Two different types of fuel priming pumps are
available. The mechanical hand prime design and the
electrically operated design.

Mechanical Operated Hand Priming
Pump

• The fuel tank is empty or the fuel tank has been
partially drained.

• The engine has been in storage.

• The fuel filter has been replaced.

• The pressure fuel lines have been disconnected.

Illustration 44 g06173517

Typical example

(1) Pump handle
(2) Body of priming pump
(3) Vent Plug

1. Ensure that the key switch is in the OFF position.
Ensure that the fuel tank is full of clean diesel fuel.
Check that the fuel supply valve (if equipped) is in
the “ON” position

2. Unlock the fuel priming pump handle (1). Turn
handle counter-clockwise. If equipped, loosen vent
plug (3) and operate priming pump handle (1) until
fuel free of air comes from vent plug (3). Tighten
vent plug (3) to a torque of 35 N·m (309 lb in).

3. Operate the fuel priming pump handle until strong
pressure is felt.

Note: The location of the fuel tank and the amount of
fuel in the fuel tank can affect the time taken to prime
the fuel system.

4. When strong pressure can be felt, press in the fuel
priming pump handle (1) and lock the handle into
the fuel pump body (2). To lock the handle, turn
handle clockwise.

78 M0080243-01

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

Note: The stronger the pressure in the fuel system
the quicker the engine will start.

NOTICE

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

5. Start the engine, refer to this Operation and
Maintenance Manual, “Starting the Engine” for
more information.

6. If the engine will not start, repeat Step 2 to Step 4.

7. Once the engine starts, allow the engine to operate

with no load for 5 minutes.

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

Electrically Operated Priming
Pump

4. If the water separator is not full of fuel, turn the fuel

priming switch (2) OFF and then turn the fuel
priming switch (2) ON. This action will cycle the
fuel priming pump again.

Note: The location of the fuel tank and the amount of
fuel in the fuel tank can affect the time taken to prime
the fuel system.

5. When the water separator is full of fuel, attempt to
start the engine. If the engine starts and the
engine runs rough or the engine misfires, operate
at low idle until the engine is running smoothly. If
the engine cannot be started, or if the engine
continues to misfire or smoke, repeat Step 2.

6. The fuel system can also be primed by using the
key switch. Turn the key to the ON position for 2
minutes. After 2 minutes the fuel system should be
primed. If necessary, by cycling the key switch the
system will prime again for 2 minutes.

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

Original Equipment Manufacture

Illustration 45 g06046130

Typical example

(1) Electric fuel priming pump
(2) Fuel priming pump switch

1. Ensure that the engine power supply is in the ON
position. The fuel system can be primed from the
keyswitch or from a remote mounted switch (2).

2. Using the fuel priming switch (2) to prime the fuel
system . Turn the fuel priming switch (2) to the ON
position. Hold the fuel priming switch in the ON
position for 2 minutes.

Original Equipment Manufacture (OEM) may have
installed fuel priming system. Refer to OEM for
priming instructions.

i06936211

Fuel System Primary Filter
(Water Separator) Element ­Replace

SMCS Code: 1260-510-FQ; 1263-510-FQ

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

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected fuel system components.

3. Verify that the water separator is full of fuel.

M0080243-01 79

Maintenance Section

Fuel System Primary Filter/Water Separator - Drain

Do not fill fuel filters with fuel before installing

NOTICE

them. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause ac­celerated wear to fuel system parts. The fuel sys-

tem should be primed prior to starting the engine.

Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,

the element should be changed before the regularly
scheduled interval.

The primary filter/water separator also provides
filtration to help extend the life of the secondary fuel
filter. The element should be changed regularly. If a
vacuum gauge is installed, the primary filter/water
separator should be changed at 50 kPa to 70 kPa
(7.25 psi to 10.15 psi).

7. The secondary fuel filter should be replaced when
the primary fuel filter is replaced. For more
information refer to this Operation and
Maintenance Manual, “Fuel System Secondary
Filter - Replace”.

8. Dispose of the fluid and old filter in accordance
with local regulations.

i06096654

Fuel System Primary Filter/
Water Separator - Drain

SMCS Code: 1260-543; 1263-543

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

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected fuel system components.

Illustration 46 g06046186

Typical example

1. Close the main fuel supply valve.

2. Place a suitable container below the primary fuel

filter to catch any fluid that may spill. Clean any
split fluid.

3. Clean the outside of the primary fuel filter.

4. Using a suitable tool, remove the spin on filter (4)

from filter base (1). Discard old filter element.

5. Ensure that the seal surface (2) is clean. Apply
clean diesel fuel to the O ring seal (3) on the new
spin on filter.

6. Install the new spin on filter to the filter base (1).
Spin on the filter until the O ring seal (3) contact
the sealing surface (2). Then, rotate the spin on
filter ¾ of a full turn.

Illustration 47 g03807817

1. Ensure that the engine is stopped. Open drain (1).
The drain is a self-ventilated drain. Catch the
draining water in a suitable container. Dispose of
the water properly.

80 M0080243-01

Maintenance Section
Fuel System Secondary Filter - Replace

2. Close drain (3).

The water separator is under suction during normal

NOTICE

engine operation. Ensure that the drain valve is tight­ened securely to help prevent air from entering the
fuel system.

i06605835

Fuel System Secondary Filter ­Replace

SMCS Code: 1261-510-SE

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

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected fuel system components.

Illustration 48 g06042986

Typical example

Note: The fuel system has two secondary filters, both
must be replaced.

3. The residual fuel pressure in the fuel system may
need relieving. Wait from 1 minute to 5 minutes
until the fuel pressure has lowered.

Ensure that the engine is stopped before any servic-

NOTICE

ing or repair is performed.

Refer to Systems Operation, Testing, and
Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the
standards of cleanliness that must be observed

during ALL work on the fuel system.

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

performing this maintenance.

2. Place a suitable container under the fuel filters to
catch any fuel that might spill. Clean up any spilled
fuel. Clean the outside body of both fuel filters.

4. Use a suitable tool remove the spin on fuel filter
(3).

5. Ensure the sealing surface (1) is clean. Lubricate
the O ring seal (2) on the new spin on filter with
clean diesel fuel.

6. Install the new spin on filter (3) to the filter base.
Spin on the filter until the O ring seal (2) contact
the sealing surface (1). Then, rotate the spin on
filter 1 full turn.

7. Replace the other secondary fuel filter, refer to
step 2 through to step 6.

8. Turn on the fuel supply valve. Dispose of the fluid
and old filters in accordance with local regulations.

9. The primary fuel filter the secondary fuel filter must
be replaced at the same time. Refer to the
Operation and Maintenance Manual, “Fuel System
Primary Filter (Water Separator) Element ­Replace”. The engine will need to be purged of air.
With primary and secondary fuel filters replace,
Refer to Operation and Maintenance Manual,
“Fuel System Prime”.

M0080243-01 81

Maintenance Section

Fuel Tank Water and Sediment - Drain

i02348492

Fuel Tank Water and Sediment

- Drain

SMCS Code: 1273-543-M&S

NOTICE
Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte-

nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain­ers before opening any compartment or disassem­bling any component containing fluids.

Dispose of all fluids according to local regulations
and mandates.

Fuel Tank

Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system.

Water can be introduced into the fuel tank when the
fuel tank is being filled.

Condensation occurs during the heating and cooling
of fuel. The condensation occurs as the fuel passes
through the fuel system and the fuel returns to the
fuel tank. This causes water to accumulate in fuel

tanks. Draining the fuel tank regularly and obtaining
fuel from reliable sources can help to eliminate water
in the fuel.

Drain the Water and the Sediment

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

supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If the
engine is equipped with this system, regular
maintenance of the fuel system filter is important.

Fuel Storage Tanks

Drain the water and the sediment from the fuel
storage tank at the following intervals:

• Weekly

• Service intervals

• Refill of the tank

This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank.

If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.

i06223506

Grounding Stud - Inspect/
Clean/Tighten

SMCS Code: 7423-079; 7423-070; 7423-040

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

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

drain valve.

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

Fill the fuel tank after operating the engine in order to
drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.

The connection of battery cables to a battery and
the disconnection of battery cables from a battery
may cause an explosion which may result in in­jury or death. The connection and the disconnec­tion of other electrical equipment may also cause
an explosion which may result in injury or death.
The procedures for the connection and the dis­connection of battery cables and other electrical
equipment should only be performed in a nonex­plosive atmosphere.

82 M0080243-01

Maintenance Section
Hoses and Clamps - Inspect/Replace

Inspect all hoses for leaks that are caused by the
following conditions:

• Cracking

• Softness

• Loose clamps

Replace hoses that are cracked or soft. Tighten any
loose clamps.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

Illustration 49 g03861473

Inspect the OEM harness for good connections.
Inspect the condition of the OEM harness.

The electronics grounding studs must have a wire
ground to the battery. Tighten the electronics
grounding studs at every oil change. Ground wires
and straps should be combined at engine grounds.
All grounds should be tight and free of corrosion.

• Clean the electronics grounding studs and the

terminals for the ground strap with a clean cloth.

• If the connections are corroded, clean the

connections with a solution of baking soda and
water.

• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
clamp.

Due to extreme temperature changes, the hose will
harden. Hardening of the hoses will cause hose
clamps to loosen. This hardening can result in leaks.
A constant torque hose clamp will help to prevent
loose hose clamps.

Each installation application can be different. The
differences depend on the following factors:

• Type of hose

• Keep the electronics grounding studs and the

strap clean and coated with MPGM grease or
petroleum jelly.

i06223511

Hoses and Clamps - Inspect/
Replace

SMCS Code: 7554-510; 7554-040

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.

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”.

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of the
fittings

Replace the Hoses and the Clamps

Refer to the OEM information for further information
on removing and replacing fuel hoses (if equipped).

The following text describes a typical method of
replacing coolant hoses. Refer to the OEM
information for further information on the coolant

system and the hoses for the coolant system.

M0080243-01 83

Maintenance Section

Overhaul Considerations

i03901481

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

pressure.

1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowly in order

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

Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.

3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: For the correct coolant, see this Operation and

Maintenance Manual, “Fluid Recommendations”.

8. Refill the cooling system. Refer to the OEM
information for further information on refilling the
cooling system.

9. Clean the cooling system filler cap. Inspect the
cooling system filler caps seals. Replace the
cooling system filler cap if the seals are damaged.
Install the cooling system filler cap.

10. Start the engine. Inspect the cooling system for
leaks.

Fuel System

The fuel system is split into two different sections,
high pressure, and low pressure. Ensure that the fuel
pressure has been purged before any parts are
removed loosened or replaced.

Check that connections and hoses are secure, check
for leaks. If parts are to be removed or tightened,

refer to the Disassembly and Assembly manual for
more information.

i05971077

Power Take-Off Clutch - Check

SMCS Code: 3055-535

NOTICE

New power take-offs should have the clutch adjust­ment checked before being placed into service. The
clutch adjustment should be checked again after the
first ten hours of operation. New clutch plates have a
“wear in” period, and the clutch may require several
adjustments until the new plates are “worn in”.

Illustration 50 g00781502

(1) Instruction plate
(2) Serial number plate

Check the clutch adjustment regularly after “wear in”.
Heavy-duty applications which have engagements
that are frequent and relatively long periods of clutch
slippage require more frequent adjustment than light­duty applications. The operating torque should be
measured in order to determine if a clutch adjustment
is required.

Refer to the OEM information and instruction plate
(1) for instructions on lubrication, adjustment, and
other recommendations for service. Perform the

maintenance that is specified on the instruction plate.

Do not operate the engine with the Instruction
Plate cover removed from the clutch. Personal in-

jury may result.

If the clutch is damaged to the point of burst fail­ure, expelled pieces can cause personal injury to
anyone in the immediate area. Proper safeguards
must be followed to help prevent accidents.

Overhaul Considerations

SMCS Code: 7595-043

For an overhaul solution, contact your Perkins
distributor.

84 M0080243-01

Maintenance Section
Radiator - Clean

i04020194

Radiator - Clean

SMCS Code: 1353-070

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.

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.

The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.

Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction of
the air flow. Hold the nozzle approximately 6 mm
(0.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes.
This movement will remove debris that is between

the tubes.

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

both sides.

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

Check the starting motor for proper operation. Check
the electrical connections and clean the electrical

connections. Refer to the Service Manual for more
information on the checking procedure and for

specifications or consult your Perkins distributors for
assistance.

i06223514

Walk-Around Inspection

SMCS Code: 1000-040

Inspect the Engine for Leaks and
for Loose Connections

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

For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or
coolant leaks, loose bolts, worn belts, loose

connections, and trash buildup. Make repairs, as
needed:

• The guards must be in the correct place. Repair
damaged guards or replace missing guards.

• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.

NOTICE

For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and
correct the leak. If leaking is suspected, check the flu­id levels more often than recommended until the leak

is found or fixed, or until the suspicion of a leak is
proved to be unwarranted.

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

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

i02568202

Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040

Perkins recommends a scheduled inspection of the
starting motor. If the starting motor fails, the engine
may not start in an emergency situation.

Accumulated grease and/or oil on an engine or deck

NOTICE

is a fire hazard. Remove this debris with steam clean­ing or high pressure water.

• Ensure that the cooling lines are correctly clamped
and that the cooling lines are tight. Check for
leaks. Check the condition of all pipes.

• Inspect the water pumps for coolant leaks.

Note: The water pump seal is lubricated by coolant in
the cooling system. A small amount of leakage is
normal as the engine cools down and the parts
contract.

M0080243-01 85

Maintenance Section

Water Pump - Inspect

Excessive coolant leakage may indicate the need to
replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/
or seals, refer to the Service Manual for the engine or
consult your Perkins distributor.

• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters, and the valve cover.

• Inspect the fuel system for leaks. Look for loose
fuel line clamps or for loose fuel line tie-wraps.

• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, and wiring harnesses.

• Inspect the alternator belt and the accessory drive
belts for cracks, breaks, or other damage.

Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on

the new belt could cause the belt to break.

• Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean
fuel enters the fuel system.

• A piston seizure

• Other potential damage to the engine

A failed water pump might cause severe engine
overheating problems. Overheating could result in
cracks in the cylinder head, a piston seizure, or other
potential damage to the engine.

Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace the
water pump. Refer to Disassembly and Assembly,
“Water Pump - Remove” and Disassembly and
Assembly, “Water Pump - Install” for the correct
procedure.

Inspect the water pump for wear, cracks, pin holes,
and proper operation. Refer to the Parts Manual for
the correct part numbers for the engine or consult a
Perkins distributor if a repair or replacement is
needed.

• Drain the water from the primary fuel filter.

• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.

• Inspect the ground strap for a good connection
and for good condition.

• Inspect the ECM to the cylinder head ground strap
for a good connection and for good condition.

• Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.

• Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that
cannot be calibrated.

i06223521

Water Pump - Inspect

SMCS Code: 1361-040

A failed water pump might cause severe engine
overheating problems that could result in the
following conditions:

• Cracks in the cylinder head

86 M0080243-01

Index Section

Index

A

After Starting Engine ....................................... 34

After Stopping Engine ..................................... 39

Air Compressor - Check (If Equipped) ............ 60

Air Tank Moisture and Sediment - Drain (If

Equipped) ...................................................... 60

B

Battery - Recycle ............................................. 60

Battery - Replace............................................. 61

Battery Electrolyte Level - Check .................... 61

Battery or Battery Cable - Disconnect............. 62

Before Starting Engine .............................. 13, 31

Belts - Inspect/Adjust/Replace ........................ 62

Adjust........................................................... 63

Inspect ......................................................... 62

Replace........................................................ 63

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

Batteries....................................................... 10

Coolant ........................................................ 10

Diesel Fuel ................................................... 10

Oils............................................................... 10

C

Cold Weather Operation ................................. 37

Cold Weather Starting ..................................... 31

Ether Injection System (If Equipped) ........... 32

Coolant (DEAC) - Change............................... 63

Drain ............................................................ 63

Fill ................................................................ 64

Flush ............................................................ 63

Coolant (ELC) - Change.................................. 64

Drain ............................................................ 65

Fill ................................................................ 65

Flush ............................................................ 65

Coolant Extender (ELC) - Add ........................ 66

Coolant Level - Check..................................... 66

Coolant Temperature Regulator - Replace ..... 66

Cooling System Supplemental Coolant

Additive (SCA) - Test/Add.............................. 67

Add the SCA, If Necessary .......................... 67

Test for SCA Concentration......................... 67

Crushing Prevention and Cutting Prevention.. 12

D

Diagnostic Lamp.............................................. 29

Driven Equipment - Check .............................. 68

E

Electrical System............................................. 14

Grounding Practices .................................... 14

Electronic Unit Injector - Check/Replace ........ 68

Emissions Certification Film ............................ 20

Engaging the Driven Equipment ..................... 35

Industrial Engines ........................................ 35

Engine - Clean................................................. 68

Engine Air Cleaner Element (Dual Element)

- Inspect/Clean/Replace ................................ 69

Cleaning the Primary Air Cleaner

Elements .................................................... 70

Servicing the Air Cleaner Elements............. 69

Engine Air Cleaner Element (Single

Element) - Inspect/Clean/Replace ................ 71

Engine Air Cleaner Service Indicator -

Inspect (If Equipped) ..................................... 72

Test the Service Indicator ............................ 72

Engine Diagnostics ......................................... 29

Engine Electronics........................................... 14

Engine Mounts - Inspect.................................. 72

Engine Oil and Filter - Change ........................ 74

Drain the Engine Lubricating Oil.................. 74

Fill the Oil Pan.............................................. 75

Oil and Filter Change Intervals .................... 74

Engine Oil Level - Check................................. 72

Engine Oil Sample - Obtain ............................. 73

Obtain the Sample and the Analysis ........... 74

Engine Operation ............................................ 35

Engine Operation with Active Diagnostic

Codes ............................................................ 29

Engine Operation with Intermittent

Diagnostic Codes .......................................... 30

Engine Starting.......................................... 13, 31

Engine Stopping ........................................ 14, 39

Engine Valve Lash - Check ............................. 76

Engine Valve Rotators - Inspect...................... 76

F

Fault Logging................................................... 29

Features and Controls..................................... 25

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

Ether ............................................................ 12

Fire Extinguisher.......................................... 12

Lines, Tubes, and Hoses ............................. 12

M0080243-01 87

Index Section

Fluid Recommendations ........................... 40, 42

ELC Cooling System Maintenance.............. 45

Engine Oil .................................................... 41

General Coolant Information ....................... 42

General Lubricant Information ..................... 40

Fluid Recommendations (General Fuel

Information) ................................................... 47

Contamination Control Recommendations for

Fuels .......................................................... 54

Diesel Fuel Characteristics.......................... 49

Diesel Fuel Requirements ........................... 47

General Information..................................... 47

Renewable and Alternative Fuels................ 55

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

California Proposition 65 Warning................. 4

Literature Information .................................... 4

Maintenance .................................................. 4

Maintenance Intervals ................................... 4

Operation ....................................................... 4

Overhaul ........................................................ 4

Safety............................................................. 4

Fuel and the Effect from Cold Weather ........... 37

Fuel Conservation Practices ........................... 35

Fuel Related Components in Cold Weather ... 37

Fuel Heaters ................................................ 38

Fuel Tanks ................................................... 37

Fuel System - Prime (General Instructions).... 77

Electrically Operated Priming Pump............ 78

Mechanical Operated Hand Priming

Pump.......................................................... 77

Original Equipment Manufacture................. 78

Priming Fuel Pumps .................................... 77

Fuel System Primary Filter (Water

Separator) Element - Replace....................... 78

Fuel System Primary Filter/Water

Separator - Drain ........................................... 79

Fuel System Secondary Filter - Replace ........ 80

Fuel Tank Water and Sediment - Drain ........... 81

Drain the Water and the Sediment .............. 81

Fuel Storage Tanks...................................... 81

Fuel Tank ..................................................... 81

G

General Information ........................................ 16

Grounding Stud - Inspect/Clean/Tighten......... 81

H

Hoses and Clamps - Inspect/Replace............. 82

Fuel System ................................................. 83

Replace the Hoses and the Clamps ............ 82

I

Important Safety Information............................. 2

L

Lifting and Storage .......................................... 21

M

Maintenance Interval Schedule....................... 59

Daily ............................................................. 59

Every 12 000 Service Hours or 6 Years....... 59

Every 2500 Service Hours........................... 59

Every 3000 Service Hours or 2 Years ......... 59

Every 4000 Service Hours........................... 59

Every 500 Service Hours............................. 59

Every 500 Service Hours or 1 Year ............. 59

Every 585,000 L (154,540 US gal) of Fuel .. 59

Every 6000 Service Hours or 3 Years ......... 59

When Required............................................ 59

Maintenance Recommendations .................... 56

Maintenance Section....................................... 40

Manual Stop Procedure .................................. 39

Model View Illustrations .................................. 16

Engine Views ............................................... 16

Monitoring System........................................... 25

Action Alert .................................................. 25

Critical Protection Override.......................... 25

Diagnostic .................................................... 26

Shutdown..................................................... 25

Shutdown Reset .......................................... 26

Standard Warning Outputs .......................... 26

Warning Alarm ............................................. 25

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

General Hazard Information.............................. 7

Containing Fluid Spillage ............................... 9

Dispose of Waste Properly .......................... 10

Fluid Penetration ........................................... 8

Inhalation ....................................................... 9

Pressurized Air and Water............................. 8

Static Electricity Hazard when Fueling with

Ultra-low Sulfur Diesel Fuel ......................... 9

O

Operation Section............................................ 21

Overhaul Considerations................................. 83

P

Plate Locations and Film Locations ................ 20

88 M0080243-01

Index Section

Power Take-Off Clutch - Check....................... 83

Product Description ......................................... 18

Aftermarket Products and Perkins

Engines ...................................................... 19

Electronic Engine Features ......................... 19

Engine Diagnostics...................................... 19

Engine Service Life...................................... 19

Engine Specifications .................................. 18

Product Identification Information ................... 20

Product Information Section............................ 16

Product Lifting ................................................. 21

Engine Lifting ............................................... 22

Product Storage .............................................. 22

Engine.......................................................... 22

R

Radiator - Clean .............................................. 84

Radiator Restrictions....................................... 37

Refill Capacities............................................... 40

Refill Capacities and Recommendations........ 40

Recommendation ........................................ 40

Refill Capacities ........................................... 40

T

Table of Contents .............................................. 3

W

Walk-Around Inspection .................................. 84

Inspect the Engine for Leaks and for Loose

Connections............................................... 84

Water Pump - Inspect...................................... 85

Welding on Engines with Electronic

Controls ......................................................... 56

S

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

2506D-E15TA Safety Label Positions ........... 5

Universal Warning (1) .................................... 6

Safety Section ................................................... 5

Self-Diagnostics .............................................. 29

Sensors and Electrical Components............... 26

Severe Service Application ............................. 57

Environmental Factors................................. 58

Incorrect Maintenance Procedures ............. 58

Incorrect Operating Procedures .................. 58

Starting Motor - Inspect................................... 84

Starting the Engine .......................................... 32

Problems with the Wiring Harness .............. 33

Starting Problems ........................................ 32

Starting the Engine ...................................... 32

Starting with Jump Start Cables (Do Not

Use This Procedure in Hazardous
Locations that have Explosive

Atmospheres) ................................................ 33

Stopping the Engine ........................................ 39

System Pressure Release............................... 56

Coolant System ........................................... 56

Engine Oil .................................................... 56

Fuel System................................................. 56

Product and Dealer Information

Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

Name: Branch:

Address:

Dealer Contact

Sales:

Phone Number Hours

Parts:

Service:

M0080243

Perkins Engines Compony Limited All Rights Reserved

90 August 2017