Perkins Engine 2806F-E18TA Service Manual

Operation and
Maintenance
Manual

M0068760 (en-us)

March 2016

2806F-E18TA Industrial Engine

P84 (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.

M0068760 3

Table of Contents

Table of Contents

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

Safety Section

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

Additional Messages ......................................... 6

General Hazard Information.............................. 6

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

Fire Prevention and Explosion Prevention...... 10

Crushing Prevention and Cutting Prevention.. 12

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

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

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

Refill Capacities............................................... 56

Maintenance Recommendations .................... 71

Maintenance Interval Schedule....................... 74

Warranty Section

Warranty Information..................................... 102

Reference Information Section

Reference Materials ...................................... 103

Index Section

Index.............................................................. 106

Electrical System............................................. 13

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

Product Information Section

Model Views .................................................... 15

Product Identification Information ................... 21

Operation Section

Lifting and Storage .......................................... 23

Features and Controls..................................... 29

Engine Diagnostics ......................................... 40

Engine Starting................................................ 44

Engine Operation ............................................ 48

Engine Stopping .............................................. 52

Cold Weather Operation ................................. 54

Maintenance Section

4 M0068760
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.

M0068760

5

Safety Section

Safety Messages

Safety Section

i06599865

Safety Messages

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.

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.

Universal Warning (1)

Illustration 2 g01370904

One safety message is on the left side of the valve
mechanism cover. One safety message is on the
right side of the engine gear case.

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.

Illustration 1 g06040012

Typical example

(1) Universal warning label
(2) Sulfuric Acid Burn label

Sulfuric Acid Burn (2)

Illustration 3 g01382725

The safety message for sulfuric acid burn is on the
side of the exhaust cooler.

6 M0068760
Safety Section

Additional Messages

This notice should be located next to the battery
disconnect switch.

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

The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sul-

fur levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid

Do not turn the battery power disconnect switch off
until indicator lamp has turned off. If the switch is
turned off when the light is illuminated then the DEF
system will not purge and DEF could freeze and
cause damage to the pump and lines.

NOTICE

may spill from the cooler during service of the en­gine. The sulfuric acid will burn the eyes, skin
and clothing on contact. Always wear the appro­priate personal protective equipment (PPE) that
is noted on a material safety data sheet (MSDS)
for sulfuric acid. Always follow the directions for

General Hazard Information

i06078546

first aid that are noted on a material safety data
sheet (MSDS) for sulfuric acid.

i06599922

Additional Messages

There are several specific messages on this engine.
The exact location of the messages and the
description of the information are reviewed in this
section. Become familiar with all messages.

Make sure that all the messages are legible. Clean
the messages or replace the messages if you cannot
read the words. Replace the illustrations if the
illustrations are not legible. When you clean the
messages, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the

messages. Loose adhesive will allow the messages
to fall.

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

Illustration 5 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.

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.

Illustration 4 g03422039

Purge notice message

• 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.

M0068760

7

Safety Section

General Hazard Information

• 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.

• Report all necessary repairs.

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

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

• 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.

• 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.

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.

• 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 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.

Illustration 6 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.

8 M0068760
Safety Section

General Hazard Information

• Use all cleaning solutions with care.

• Report all necessary repairs.

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

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

• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. 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).

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.

Illustration 7 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.

M0068760 9

Safety Section

General Hazard Information

• Avoid brushing materials that contain asbestos.

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

• 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

Illustration 8 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.

Illustration 9 g00706404

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

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

Diesel Exhaust Fluid

Diesel Exhaust Fluid (DEF) may cause eye irritation
and can be moderately irritating to the skin. Exposure
to decomposition products may cause a health
hazard. Serious effects may be delayed following

exposure.

10 M0068760
Safety Section

Burn Prevention

DEF is not expected to produce significant adverse
health effects when the recommended instructions

for use are followed.

• Do not breathe DEF vapor or mist.

• Do not eat, drink, or smoke when using DEF.

• Avoid DEF contact with eyes, skin, and clothing.

• Wash thoroughly after handling DEF.

i06086863

Burn Prevention

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.

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

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

Engine and Aftertreatment System

Do not touch any part of an operating engine or
engine aftertreatment system. Allow the engine or the
engine aftertreatment system to cool before any
maintenance is performed on the engine or the
engine aftertreatment system. Relieve all pressure in
the appropriate system before any lines, fittings, or
related items are disconnected.

Aftertreatment System and Diesel
Exhaust Fluid

Diesel Exhaust Fluid (DEF) temperatures can reach
65° to 70°C (149.° to 126°F) during normal engine
operation. Stop the engine. Wait for 15 minutes in
order to allow the DEF system to be purged and the
DEF to cool before service or repair is performed.

i05945996

Fire Prevention and Explosion
Prevention

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

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.

Illustration 10 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.

After the emergency stop button is operated, ensure
that you allow 15 minutes, before the engine covers
are removed.

M0068760 11

Safety Section

Fire Prevention and Explosion Prevention

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.

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.

Illustration 11 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.

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.

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.

12 M0068760
Safety Section

Crushing Prevention and Cutting Prevention

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.

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

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

Illustration 12 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.

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

• 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.

i02143194

Crushing Prevention and
Cutting Prevention

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

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

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

Ether is flammable and poisonous.

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

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.

M0068760 13

Safety Section

Mounting and Dismounting

i05768982

Mounting and Dismounting

Do not climb on the engine or the engine
aftertreatment system. The engine and
aftertreatment system 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.

i04257031

Before Starting Engine

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 to 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 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.

i02583384

Engine Starting

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

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

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's 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 well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.

Note: The engine may be equipped with a device for
cold starting. If the engine will be operated in very
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.

i06088340

Electrical System

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.

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.

14 M0068760
Safety Section

Engine Electronics

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 “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.

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.

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

• 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.

i06091234

Engine Electronics

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 Engine 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.

M0068760 15

Product Information Section

Model Views

Product Information
Section

Model Views

i06609024

Model View Illustrations

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

Engine Views

Illustration 13 g06045642

Typical example

(1) Drive belt
(2) Refrigerant compressor
(3) Valve mechanism cover
(4) Fuel pump
(5) Breather outlet hose

(6) NOx Reduction System (NRS) valve
(7) Electronic control modules
(8) Starting motor
(9) Air intake
(10) Secondary fuel filters

(11) Adaptor of oil drain
(12) Alternator
(13) Vibration damper
(14) Belt tensioner

16 M0068760
Product Information Section

Model View Illustrations

Illustration 14 g06045668

Typical example

(15) Turbocharger
(16) Coolant outlet
(17) Water temperature regulator housing
(18) Oil filler cap
(19) Coolant pump

(20) Oil gauge (Dipstick)
(21) Coolant intake
(22) Oil filters
(23) Oil sample valve
(24) Oil cooler

(25) Fuel priming pump and primary fuel

filter

(26) NRS cooler

M0068760 17

Product Information Section

Model View Illustrations

Aftertreatment System

The aftertreatment items are supplied loose by
Perkins.

Clean Emission Module

Illustration 15 g06044166

Typical example

(1) Clean Emission Model (CEM)
(2) Exhaust outlet
(3) Selective Catalytic Reduction (SCR)

(4) DEF Injector
(5) Diesel Particulate Filter (DPF).
(6) CEM sensors and fuel system

(7) Aftertreatment Regeneration Device

(ARD)

(8) Exhaust Inlet

18 M0068760
Product Information Section

Product Description

Pump Electronic Tank Unit (PETU)

NOx Sensors and DEF Heated line

Illustration 17 g06044238

Typical example

(1) NOx sensors
(2) DEF heated line

Illustration 16 g06044127

Typical example

(1) DEF pump electronics containing filter
(2) DEF tank header
(3) DEF filler cap
(4) DEF tank drain
(5) DEF tank

i06601272

Product Description

The Perkins 2806F-E13TA Industrial Engine have the
following characteristics:

• Four-stroke cycle

• Mechanically actuated, electronically controlled
fuel injection system

• Turbocharged

• Air to air charged cooled

• Aftertreatment system

The Clean Emissions Module (CEM) is constructed
of four main items, the diesel Aftertreatment

Regeneration Device (ARD) oxidation catalyst, the
diesel particulate filter, and the Selective Catalytic
Reduction (SCR). The SCR requires the use of
Diesel Exhaust Fluid (DEF) to be injected into the
system in order to lower the emissions from the
engine. The (DEF) is stored and controlled by the
pump electronic tank unit. The DEF tank can be
installed separate from the electronic pump unit.

M0068760 19

Product Information Section

Product Description

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 18 g01387009

Cylinder and valve location

(A) Exhaust valve
(B) Inlet valve

Table 1

Engine Specifications

Engine

Arrangement and Cylinders In-Line 6 cylinder

Bore 145 mm (5.7 inch)

Stroke 183 mm (7.2 inch)

Aspiration

2806F

ATAAC

(1)

• Torque rise shaping

• Injection timing control

• System diagnostics

• Aftertreatment regeneration control

• NOX reduction system control

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.

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

Displacement 18.1 L (1105 cubic inch)

Firing Order

Rotation (flywheel end)

(1)

Air-to-air aftercooled

1-5-3-6-2-4

Counterclockwise

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

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.

20 M0068760
Product Information Section

Product Description

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.

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.

M0068760 21

Product Information Section

Product Identification Information

Product Identification
Information

i06601446

Plate Locations and Film
Locations

Illustration 19 g06040639

(1) Serial number plate
(2) Information plate

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

Illustration 20 g01403841

Serial number plate

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

The engine information plate is on top of the valve
cover near the middle of the engine.

The following information is on the information plate:
engine serial number, engine model, engine
arrangement number, maximum altitude of the
engine that is necessary to achieve the rated power,
horsepower, high idle, full load rpm, fuel settings, and
other information

The Clean Emission Module (CEM) identification
plate is on the bracket assembly on the CEM.

22 M0068760
Product Information Section

Emissions Certification Film

Illustration 21 g06040627

(3) CEM Identification plate

Illustration 22 g02236574

CEM identification plate

The CEM identification plate contains the following
information: part number, serial number, change
level, and configuration ID code. This information
may be needed by the Perkins distributor when
inquiries are being made on the CEM.

Illustration 23 g06040642

Typical example

(4) PETU Plate location

Illustration 24 g03049116

Typical example PETU serial plate

Record the information on the CEM and PETU serial
plates. The information will be required by your

Perkins distributor to identify replacement part
numbers.

Pump Electronic Tank Unit (PETU)
and Pump Electronic Unit (PEU)

Note: Some applications may not have a diesel

exhaust fluid tank installed into to the electronic unit.

i05951816

Emissions Certification Film

Note: This information is pertinent in the United

States, in Canada and in Europe.

The emissions label is located on the top of the valve
mechanism cover.

M0068760 23

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i06602132

Product Lifting

Illustration 25 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

24 M0068760
Operation Section

Product Lifting

Engine Lifting

Illustration 26 g06044076

Typical example

(1) Engine lifting eyes

M0068760 25

Operation Section

Product Storage

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

Radiator Only

Detach the radiator, and mounting bracket at the
engine front support. Add eyebolts or lifting brackets
to the threaded holes marked for lifting.

Clean Emission Module (CEM)
Lifting

Ensure that all 4 lifting eyes are used when lifting the
CEM. Only use the lifting eyes (1) and lifting eyes (2)
for lifting the CEM, refer to illustration 27 .

Pump Electronic Tank Unit (PETU)

Illustration 27 g06042325

Typical example

(1) CEM lifting eyes
(2) CEM lifting eyes

Illustration 28 g06041037

Typical example

(1) PETU lifting eyes

i06605082

Product Storage

(Engine and Aftertreatment)

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

Some applications, the engine can be equipped with
delayed engine shutdown. Allow at least 2 minutes
after the engine has stopped before you turn the
battery disconnect switch to OFF. Disconnecting the
battery power too soon will prevent purging of the
DEF fluid lines after the engine is shut down. Also,
during the 2 minutes the engine electronic control
module is active storing information from the engine
and aftertreatment sensors.

Condition for Storage

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

26 M0068760
Operation Section

Engine and Aftertreatment

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 Volatile Corrosion Inhibitor (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.

Note: The mixture of VCI oil can be added to the inlet
by removing the plug for checking turbocharger boost
pressure. 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. Remove the fuel from the secondary fuel filter
housing. Alternately, empty and reinstall the spin­on fuel filter element 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 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 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 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 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 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 whilst 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 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 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 to check the engine for corrosion.
If the engine has signs of corrosion, repeat the
protection procedure.

M0068760 27

Operation Section

Engine and Aftertreatment

Coolant System

Completely fill the cooling system before storage.

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

coolants.

Aftertreatment

The engine must be allowed to perform a Diesel
Exhaust Fluid (DEF) purge before the battery
disconnect switch is turned off. Some applications,
the engine can be equipped with delayed engine
shutdown. Allow 2 minutes after the engine has
stopped before disconnecting the battery disconnect
switch.

The exhaust outlet of the aftertreatment must be
capped. To prevent damage to the exhaust outlet

connection during storage, the weight of the CEM
must not act on the exhaust outlet.

1. Ensure normal engine shutdown, allow the DEF to
be purged. Do not disconnect the battery
disconnect switch, allow 2 minutes after key off
before disconnection.

2. Fill the tank with DEF that meets all the
requirement defined in ISO 22241-1.

3. Ensure that all DEF lines and electrical connection
are connected prior to prevent crystal from
forming.

4. Ensure that the DEF filler cap is correctly installed.

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 to turn the engine in the
normal direction of rotation. The procedure
ensures that no hydraulic locks or resistance exist.

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 to
prevent damage to the mechanism.

Illustration 29 g06042459

Typical example

(1) Plug

8. If an engine is stored for more than 1 year, Perkins
recommends Pre lubrication of the engine to avoid
dry starting. Use a suitable pump 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 to lubricate the
internal surfaces.

Remove one of the plugs shown in illustration 29
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.

28 M0068760
Operation Section

Engine and Aftertreatment

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.

Remove Aftertreatment from Storage

DEF has a limited life, refer to table 2 for the time and
temperature range. DEF that is outside this range

MUST be replaced.

On removal from storage the DEF quality in the tank
must be tested with a refractometer. The DEF in the

tank must meet the requirements defined in ISO
22241-1 and comply with table 2 .

1. If necessary, drain the tank and fill with DEF that
meets ISO 22241-1.

2. Replace the DEF filter, refer to this Operation, and
Maintenance Manual, “Diesel Exhaust Fluid Filter­Clean/Replace”.

3. Ensure that the drive belt is correctly installed.
Ensure that all engine coolant and engine oil has
the correct specification and grade. Ensure that
the coolant and the engine oil are at the correct
level. Start the engine. If a fault becomes active
turn off the engine, allow 2 minutes for the DEF
system to purge, then restart the engine.

4. If the fault continues to stay active, refer to
Troubleshooting for more information.

Table 2

DEF Storage

Temperature Duration

10° C (50° F) 36 months

25° C (77° F) 18 months

30° C (86° F) 12 months

35° C (95° F)

(1)

At 35° C, significant degradation can occur. Check every batch
before use.

(1)

6 months

M0068760 29

Operation Section

Features and Controls

Features and Controls

i06163203

Monitoring System

The monitoring system is designed to alert the
operator to an immediate problem with any of the
engine systems that are monitored. The monitoring
system is also designed to alert the operator to an
impending problem with any of the engine systems
that are monitored. The monitoring system can be
accessed by the electronic service tool. For more
information on the electronic service tool, refer to

Troubleshooting , “Electronic Tools”.

Monitoring System Indicators

Engine Malfunction – This indicator
illuminates when there is a fault with the
engine or after treatment system.

Engine STOP – This indicator will
illuminate solid when a level 3 warning
fault has been detected by the

monitoring system.

Note: Some items have been removed from engine

for clarity.

Diesel Particulate Filter (DPF) – This
indicator will illuminate in order to show
that a regeneration is needed.

Regeneration Active – This indicator will
illuminate in order to show that a
regeneration is active and exhaust

temperatures are elevated.

Diesel Exhaust Fluid (DEF) Level – This
gauge shows the amount of DEF in the
DEF tank.

Emission Malfunction Indicator – This
indicator will illuminate when an

emissions system related to DEF or SCR
has failed. Refer to Operation and Maintenance
Manual, “Selective Catalytic Reduction Warning
System” for more information.

i06617615

Sensors and Electrical
Components

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.

30 M0068760
Operation Section

Sensors and Electrical Components

Engine

Illustration 30 g06048161

Typical example

(1) Secondary Speed/timing sensor
(2) Boost pressure sensor
(3) Inlet air temperature sensor
(4) NOx Reduction System (NRS) solenoid
(5) NRS pressure sensor
(6) NRS differential pressure sensor

(7) NRS temperature sensor
(8) Air control solenoid valve
(9) Electronic control module
(10) Starter solenoid and starting motor
(11) Oil pressure sensor
(12) Barometer pressure sensor

(13) Fuel pressure sensor
(14) Fuel temperature sensor
(15) Primary speed/timing sensor
(16) Alternator
(17) Refrigerant compressor

M0068760 31

Operation Section

Sensors and Electrical Components

Illustration 31 g06048567

Typical example

(18) Coolant temperature sensor

32 M0068760
Operation Section

Sensors and Electrical Components

Illustration 32 g06049146

Typical example

(19) Location for Top Dead Center (TDC) probe

Aftertreatment System

Illustration 33 g06048751

Typical example

(1) Diesel Exhaust Fluid (DEF) injector
(2) Temperature sensor

(3) Coil for spark plug

M0068760 33

Operation Section

Sensors and Electrical Components

(4) Diesel Particulate Filter (DPF)

Differential pressure sensor
(5) DPF pressure sensor
(6) Temperature sender

(7) 40-Pin connector
(8) Selective Catalytic Reduction (SCR)

temperature sensor

(9) Fuel pilot pressure sensor

Pump Electronic Tank Unit (PETU)

(10) Fuel main pressure sensor
(11) Identification Module
(12) Temperature sender for Aftertreatment

Regeneration Device (ARD)

Illustration 34 g03393959

Typical example

(1) DEF Level Sensor and DEF Temperature

Sensor
(2) Coolant Diverter Valve

(3) Customer Connections
(4) Dosing Control Module
(5) Relays

(6) Voltage Limiting Protection Module

34 M0068760
Operation Section

Battery Disconnect Switch

i05422613

Battery Disconnect Switch

(If Equipped)

Illustration 35 g03422039

NOTICE

Do not turn off the battery disconnect switch until the
indicator lamp has turned off. If the switch is turned
off when the indicator lamp is illuminated the Diesel
Exhaust Fluid (DEF) system will not purge the DEF. If
the DEF does not purge, DEF could freeze and dam­age the pump and lines.

NOTICE

Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam­age to the electrical system could result.

The battery disconnect switch and the engine start
switch perform different functions. The entire
electrical system is disabled when you turn the
battery disconnect switch to the OFF position. The
battery remains connected to the electrical system
when you turn the engine start switch to the OFF
position.

Turn the battery disconnect switch to the OFF
position and remove the key when you service the
electrical system or any other engine components.

Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key after
you operate the engine. This will prevent the battery
from being discharged. The following problems can
cause battery discharge:

• short circuits

• current draw via some components

• vandalism

i06605661

Selective Catalytic Reduction
Warning System

The selective catalytic reduction (SCR) system is a
system used to reduce NOx emissions from the
engine. Diesel exhaust fluid (DEF) is pumped from
the DEF tank and is sprayed into the exhaust stream.
The DEF reacts with the SCR catalyst to reduce NOx
and leaves a nitrogen and water vapor. The Exhaust
Gas Recirculation (EGR) system cools, measures,
and introduces recalculated exhaust gas into the
intake manifold to aid in NOx reduction.

Battery Disconnect Switch – The battery
disconnect switch can be used in order

to disconnect the battery from the
engines electrical system. The key must be
inserted into the battery disconnect switch
before the battery disconnect switch can be
turned.

ON – To activate the electrical system,

insert the disconnect switch key and

turn the battery disconnect switch
clockwise. The battery disconnect switch must
be turned to the ON position before you start the
engine.

OFF – To deactivate the electrical

system, turn the battery disconnect

switch counterclockwise to the OFF
position.

Stopping the engine immediately after the engine has

NOTICE

been working under load can result in overheating of
SCR components.

Refer to the Operation and Maintenance Manual,
“Engine Stopping” procedure to allow the engine to
cool and to prevent excessive temperatures in the
turbocharger housing and the DEF injector.

NOTICE

Allow at least 2 minutes after shutting down the en­gine before you turn the battery disconnect switch to
OFF. Disconnecting the battery power too soon will
prevent purging of the DEF lines after the engine is
shutdown.

Definitions

Observe the following definitions.

M0068760 35

Operation Section

Selective Catalytic Reduction Warning System

Self-correct – Fault condition no longer exists. An
active fault code will no longer be active.

Notification – Action taken by the system to alert the
operator of pending Inducement.

Inducement – Engine derates, vehicle speed limits,
or other actions intended to prompt the operator to
repair or maintain the emission control system.

Inducement Categories – The Inducements are
separated into categories. DEF Level has its own
inducement fault codes and is separate from the
other inducement categories. Whilst DEF level
inducements aresimply based on the DEF level, the
other inducement categories are based on escalating
time. The escalating time inducements will always
have an associated fault code along with the
inducement fault code. The associated fault is the

root cause. The escalating time inducement fault
code is just an indicator of what level of inducement
the engine is in and how much time remains until the
next level of inducement. There are three inducement

categories (two for European Union) that will trigger
an escalating time inducement fault code.

Illustration 36 g03676102

DEF Level Normal

Inducement Strategy for DEF Level
(European Union)

Note: The associated codes for each of the

escalating time categories can be found in the
Troubleshooting Guide under SCR Warning System
Problem.

First occurrence – When an escalating time
inducement fault code becomes active for the first

time.

Repeat occurrence – When any escalating time
inducement fault code becomes active again within
40 hours of the first occurrence. Engine must run for
40 hours without tripping any escalating time
inducement fault before it can get back on first
occurrence times.

Safe Harbor Mode (Worldwide) – Safe Harbor
Mode is a 20 minute engine run time period that the
engine can be operated with full power after reaching
a level 3 inducement. Once in level 3 inducement, the

operator can perform a key cycle and the engine will
enter Safe Harbor Mode. Safe Harbor Mode can only
be implemented once. Safe Harbor Mode is not
allowed for DEF level inducements with Worldwide

configuration.

Safe Harbor Mode (European Union) – Safe
Harbor Mode is a 30 minute engine run time period
that the engine can be operated with full power after
reaching a level 3 inducement. Once in level 3
inducement, the operator can perform a key cycle
and the engine will enter Safe Harbor Mode. Safe
Harbor Mode can only be implemented up to three
times.

Illustration 37 g03676107

If the DEF level falls below 20%, an amber indicator
will illuminate next to the DEF level gauge on the

dash. To avoid further inducements, turn the key to
the OFF position and add DEF to the DEF tank.

36 M0068760
Operation Section

Selective Catalytic Reduction Warning System

Illustration 38 g03676111

If the DEF level falls below 13.5%, a level 1
inducement event will occur. The check engine lamp

and the emissions malfunction indicator lamp will
illuminate. The amber indicator next to the DEF level

gauge on the dash will remain lit.

Illustration 39 g03676123

Reduced Performance

When the ECM is configured to "Reduced
Performance" and the DEF level is below 1%, the

engine will be in level 2 inducement. The check
engine lamp and emissions malfunction indicator
lamp will illuminate and flash slowly. The DEF level
gauge amber lamp will remain lit. The engine will
have a 50% derate. When the DEF tank has been

emptied of all DEF, the engine will have a 100%
derate and be limited to 1000 rpm or low idle,
whichever is greater. No further inducement action
will occur for "Reduced Performance" configuration.
Safe Harbor Mode is allowed for three key cycles.

Illustration 40 g03676127

Reduced Time

If the ECM is configured to “Reduced Time” and the
DEF level is 0%, the engine will be in level 3
inducement. The check engine lamp and emissions
malfunction indicator lamp will illuminate and flash at
a fast rate. A red stop lamp will illuminate solid. The
DEF level gauge amber lamp will remain lit. The
engine will have a 100% derate and be limited to
1000 rpm or low idle, whichever is greater. If the final
inducement action in ET is set to “Idle Down” , then

the engine will continue to idle at derated condition. If
set to “Shutdown” , engine will shutdown after 5
minutes. Safe Harbor Mode is allowed for three key
cycles. After Safe Harbor Mode is completed, the
engine will return to idle or shutdown. If in shutdown
configuration, the engine may be restarted, but will
only run for 5 minutes at derated condition before
shutting down again. This action will continue until
the issue is resolved.

Note: Turn the key to the OFF position and add DEF
to the DEF tank to reset the DEF level inducement.

Inducement Strategy for Escalating
Time Inducement Faults (European
Union)

Reduced Time

When the ECM is configured to “Reduced Time” and
the DEF level is below 7.5%, the engine will be in
level 2 inducement. The check engine lamp and
emissions malfunction indicator lamp will illuminate
and flash slowly. The DEF level gauge amber lamp
will remain lit.

Illustration 41 g03677836

Reduced Performance

M0068760 37

Operation Section

Selective Catalytic Reduction Warning System

The check engine and emissions malfunction
indicator lamp will illuminate for a level 1 inducement­related fault. There are two inducement categories. If
the inducement is a result of a category 1 fault, then a
level 1 inducement will occur for a duration of 36

hours. If the inducement is a result of a category 2
fault, then a level 1 inducement will occur for a

duration of 10 hours. There is no repeat occurrence
for level 1 faults.

Reduced Time

The check engine and emissions malfunction
indicator lamp will illuminate for a level 1 inducement­related fault. There are two inducement categories. If
the inducement is a result of a category 1 fault, then a
level 1 inducement will occur for a duration of 18

hours. If the inducement is a result of a category 2
fault, then a level 1 inducement will occur for a

duration of 5 hours. There is no repeat occurrence for
level 1 faults.

Illustration 42 g03676138

Reduced Performance

If a fault condition exists for the entire duration of
inducement level 1, the strategy advances to

inducement level 2. The check engine lamp and the
emissions malfunction indicator lamp will illuminate
and flash slowly. If the inducement is a result of a
category 1 fault, then a level 2 inducement will occur
for a duration of 64 hours for first occurrence. For

repeat occurrence, a category 1 level 2 inducement
fault will occur for a duration of 5 hours.

If the inducement is a result of a category 2 fault, then
a level 2 inducement will occur for a duration of 10

hours. For repeat occurrence, a category 2 level 2
inducement fault will occur for a duration of 2 hours.

If the inducement is a result of a category 2 fault, then
a level 2 inducement will occur for a duration of 5

hours. For repeat occurrence, a category 2 level 2
inducement fault will occur for a duration of 1 hour.

Illustration 43 g03676141

Reduced Time

If configured to “Reduced Time” and a fault condition
exists for the entire duration of inducement level 2,

the strategy advances to inducement level 3.
Inducement level 3 has the same actions for all

categories. The check engine lamp and emissions
malfunction indicator lamp will flash at a fast rate. A
red stop lamp will also illuminate solid. The engine
will have a 100% derate and be limited to 1000 rpm
or low idle, whichever is greater. If the final
inducement action in ET is set to “Idle Down” , then

engine will continue to idle at derated condition. If set
to “Shutdown” , engine will shutdown after 5 minutes.
A key cycle will allow safe harbor mode to initiate.
Safe harbor is allowed up to three times. After safe
harbor, the engine will be in level 3 final inducement.
If set to “Shutdown” , the engine may be restarted,
but will only run for 5 minutes at derated condition
before shutting down again. This action will continue
until the issue is resolved.

Note: Contact your Perkins dealer for repairs if a fault
occurs.

Inducement Strategy for DEF Level
(Worldwide)

The engine will have a 50% derate. If the fault is not
corrected before the inducement duration ends, the

engine will become 100% derated and be limited to
1000 rpm or low idle, whichever is greater. No further
inducements will occur for “Reduced Performance”

configuration. Safe Harbor Mode is allowed for three
key cycles.

Reduced Time

If a fault condition exists for the entire duration of
inducement level 1, the strategy advances to

inducement level 2. The check engine lamp and the
emissions malfunction indicator lamp will illuminate
and flash slowly. If the inducement is a result of a
category 1 fault, then a level 2 inducement will occur
for a duration of 18 hours for first occurrence. For

repeat occurrence, a category 1 level 2 inducement
fault will occur for a duration of 108 minutes.

Illustration 44 g03676164

If the DEF level falls below 20%, an amber indicator
will illuminate next to the DEF level gauge on the

dash. To avoid inducements, turn the key to the OFF
position and add DEF to the DEF tank.

38 M0068760
Operation Section

Selective Catalytic Reduction Warning System

Illustration 45 g03676169

If the DEF level falls below 13.5%, a level 1
inducement event will occur. The check engine lamp

and the emissions malfunction indicator lamp will
illuminate. The amber indicator next to the DEF level

gauge on the dash will remain lit.

Illustration 46 g03676174

If the DEF level is below 7.5%, a level 2 inducement
event will occur. The check engine lamp and the

emissions malfunction indicator lamp will illuminate
and flash slowly. The amber indicator next to the DEF
level gauge on the dash will remain lit. If the ECM is
configured to “Reduced Performance” and the DEF
level has reached 1%, the machine will be limited to

75% torque.

Illustration 47 g03676210

If the ECM is configured to “Reduced Performance”
and the DEF tank has been emptied of all DEF, the
engine will be in a level 3 final inducement. If the
ECM is configured to “Reduced Time” and the DEF
level is 3%, the engine will be in a level 3 final
inducement. The check engine lamp and the
emissions malfunction indicator lamp will flash at a
fast rate and a red stop lamp will illuminate solid. The
engine will be taken too low idle or will be shutdown.
Once shutdown, the engine can be restarted for 5
minute periods at reduced speed and torque. If set to
idle, the engine will idle indefinitely at reduced torque.
The amber indicator next to the DEF level gauge on
the dash will remain lit.

Note: Turn the key to the OFF position and add DEF
to the DEF tank to reset the DEF level inducement.

Inducement Strategy for Escalating
Time Inducement Faults
(Worldwide)

Illustration 48 g03676215

Reduced Performance

The check engine and emissions malfunction
indicator lamp will illuminate for a level 1 inducement­related fault. There are three inducement categories.
If the inducement is a result of a category 1 fault, then
a level 1 inducement will occur for a duration of 2.5

hours for first occurrence. For repeat occurrence, a
category 1 level 1 inducement fault will occur for a
duration of 5 minutes.

M0068760 39

Operation Section

Selective Catalytic Reduction Warning System

If the inducement is a result of a category 2 fault, then
a level 1 inducement will occur for a duration of 10

hours. There is no repeat occurrence for category 2,
level 1 inducement faults.

If the inducement is a result of a category 3 fault, then
a level 1 inducement will occur for a duration of 36

hours. There is no repeat occurrence for category 3,
level 1 inducement faults.

Reduced Time The check engine and emissions
malfunction indicator lamp will illuminate for a level 1
inducement-related fault. There are three inducement

categories. If the inducement is a result of a category
1 fault, then a level 1 inducement will occur for a

duration of 2.5 hours for first occurrence. For repeat
occurrence, a category 1 level 1 inducement fault will
occur for a duration of 5 minutes.

If the inducement is a result of a category 2 fault, then
a level 1 inducement will occur for a duration of 5

hours. There is no repeat occurrence for category 2,
level 1 inducement faults.

If the inducement is a result of a category 3 fault, then
a level 1 inducement will occur for a duration of 18

hours. There is no repeat occurrence for category 3,
level 1 inducement faults.

Illustration 49 g03676215

Reduced Performance If a fault condition exists for
the entire duration of inducement level 1, the strategy

advances to inducement level 2. The check engine
and emissions malfunction indicator lamp will
illuminate and flash slowly for a level 2 inducement­related fault. The engine will have a 50% derate. If
the inducement is a result of a category 1 fault, then a
level 2 inducement will occur for a duration of 70

minutes for first occurrence. For repeat occurrence, a
category 1 level 2 inducement fault will occur for a
duration of 5 minutes.

If the inducement is a result of a category 2 fault, then
a level 2 inducement will occur for a duration of 10

hours. For repeat occurrence, a category 2 level 2
inducement fault will occur for a duration of 2 hours.

The check engine and emissions malfunction
indicator lamp will illuminate for an inducement­related fault. There are three inducement categories.
If the inducement is a result of a category 1 fault, then
a level 1 inducement will occur for a duration of 2.5

hours for first occurrence. For repeat occurrence, a
category 1 level 1 inducement fault will occur for a
duration of 5 minutes.

If the inducement is a result of a category 2 fault, then
a level 1 inducement will occur for a duration of 5

hours. There is no repeat occurrence for category 2,
level 1 inducement faults.

If the inducement is a result of a category 3 fault, then
a level 1 inducement will occur for a duration of 18

hours. There is no repeat occurrence for category 3,
level 1 inducement faults.

Illustration 50 g03676218

If a fault condition exists for the entire duration of
inducement level 2, the strategy advances to

inducement level 3. Inducement level 3 has the same
actions for all categories. The check engine lamp and

the emissions malfunction indicator lamp will flash at
a fast rate. A red stop lamp will illuminate solid. The
engine will have a 100% derate and be limited to
1000 rpm or low idle, whichever is greater. If the final
inducement action in ET is set to "Idle Down", then

engine will continue to idle at derated condition. If set
to "Shutdown" , engine will shutdown after 5 minutes.
A key cycle will allow safe harbor mode to initiate.
Safe harbor is only allowed once. After safe harbor,
the engine will be in level 3 final inducement. If set to
"Shutdown", the engine may be restarted, but will
only run for 5 minutes at derated condition before
shutting down again. This action will continue until
the issue is resolved.

Note: Contact your Perkins dealer for repairs if a fault
occurs.

If the inducement is a result of a category 3 fault, then
a level 2 inducement will occur for a duration of 64

hours. For repeat occurrence, a category 3 level 2
inducement fault will occur for a duration of 5 hours.

Reduced Time

40 M0068760
Operation Section

Engine Diagnostics

Engine Diagnostics

i05194988

Self-Diagnostics

Perkins Electronic Engines have the capability to
perform a self-diagnostics test. When the system
detects an active problem, a diagnostic lamp is
activated. Diagnostic codes will be stored in
permanent memory in the Electronic Control Module
(ECM). The diagnostic codes can be retrieved by
using Perkins electronic service tools.

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

i06193980

Configuration Parameters

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

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

System Configuration Parameters

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

• 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.

i05406659

Fault Logging

The system provides the capability of Fault Logging.
When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be
logged in the memory of the ECM. The codes that
have been logged by the ECM can be identified by
the electronic service tool. The active codes that

have been logged will be cleared when the fault has
been rectified or the fault is no longer active. The
following logged faults 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.

M0068760 41

Operation Section

Configuration Parameters

Table 3

System Configuration Parameters

Configuration Parameters Record

Engine Serial Number

Rating

Full Load Setting

Full Torque Setting

ECM Software Release Date

Customer Specified Parameters

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

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

Customer parameters may be changed repeatedly as
operational requirements change.

Table 4

Customer Specified Parameters

Specified Parameters Record

Top Engine Limit 1900 rpm

Low Idle Speed 600 rpm

Top Engine Limit 2090 rpm

Engine Acceleration Rate 2000 rpm/s

Engine Speed Decelerating Ramp Rate 2000rpm/s

Ether Start Aid Configuration Not Installed

Crankcase Pressure Sensor Installation Status Not Installed

Ambient Air Temperature Sensor Installation Status Not Installed

Engine Idle Shutdown Enable Status Disabled

Engine Idle Shutdown Delay Time 5.0 min

Engine Idle Shutdown Ambient Temperature Override Enable Status Disabled or Not Installed

Delayed Engine Shutdown Enable Status Disabled

Delayed Engine Shutdown Maximum Time 7.0 min

Aftertreatment #1 DEF Dosing Line Purge Required Air Temperature
Threshold

Delayed Engine Shutdown Aftertreatment Outlet Gas Temperature
Threshold

Engine Performance Run Out Control Configuration Not Installed

5° C (41° F)

400° C (752° F)

Engine Governor Mode Override Switch Installation Status Not Installed

(continued)

42 M0068760
Operation Section

Configuration Parameters

(Table 4, contd)

Transmission Default Torque Limit Reset Not Reset

Air Filter Restriction Switch Installation Status Not Installed

Air Filter Restriction Switch Configuration Normally Open

Intermediate Engine Speed 1400. rpm

Air Shutoff Disabled

Air Intake Shutoff Detection Installation Status Not Installed

Coolant Level Sensor Not Installed

Engine Retarder Enable Command Disabled

Auxiliary Temperature Sensor Installation Status Not Installed

Auxiliary Temperature Sensor #2 Installation Status Not Installed

Auxiliary Pressure Sensor Installation Status Not Installed

Engine Governor Primary Mode Configuration Speed Control

DPF Regeneration Enable Input Configuration CAN Input

Limp Home Desired Engine Speed 1200. rpm

Limp Home Engine Speed Ramp Rate 200. rpm/s

Throttle Input Low Idle Duty Cycle Setpoint 10 Percent

Throttle Input High Idle Duty Cycle Setpoint 90 Percent

Throttle Input #2 Low Idle Duty Cycle Setpoint 10 Percent

Throttle Input #2 High Idle Duty Cycle Setpoint 90 Percent

Throttle Failure Mode Latch Enable Status Enabled

Throttle #1 Engine Speed Droop 5 Percent

Throttle #2 Engine Speed Droop 5 Percent

Data Link Engine Speed Droop 5 Percent

Droop No Load Fuel Offset 0 Percent

Throttle Lock Feature Installation Status Not Installed

PTO Mode Set/Resume

Throttle Lock Engine Set Speed #1 600 rpm

Throttle Lock Engine Set Speed #2 600 rpm

Throttle Lock Increment Speed Ramp Rate 400. rpm/s

Throttle Lock Decrement Speed Ramp Rate 400 rpm/s

Throttle Lock Engine Set Speed Increment 10. rpm

Throttle Lock Engine Set Speed Decrement 10. rpm

Engine Fan Control Off

Engine Fan Type Configuration Variable Hydraulic

Engine Fan Speed Control Configuration Disabled or Not Installed

Engine Fan Reversing Feature Disabled

(continued)

M0068760 43

Operation Section

Configuration Parameters

(Table 4, contd)

Engine Fan Manual Purge Disabled

Engine Fan Suspend Purge Disabled

Engine Fan Purge Cycle Interval 1200 sec

Engine Fan Purge Cycle Duration 180.0sec

Engine Fan Control Charge Air Cooler Outlet Temperature Input
Enable

Engine Cooling Fan Maximum Air Flow Charge Air Cooler Outlet
Temperature

Engine Cooling Fan Minimum Air Flow Charge Air Cooler Outlet
Temperature

Engine Cooling Fan Control Coolant Temperature Input Enable Status Enabled

Engine Cooling Fan Maximum Air Flow Coolant Temperature 100° C (212° F)

Engine Cooling Fan Minimum Air Flow Coolant Temperature 90° C (194° F)

Engine Cooling Fan Control Transmission Oil Temperature Input Ena­ble Status

Engine Cooling Fan Control Hydraulic Oil Temperature Input Enable
Status

Engine Cooling Fan Control Auxiliary #1 Temperature Input Enable
Status

Engine Cooling Fan Control Auxiliary #2 Temperature Input Enable
Status

Maintenance Indicator Mode Off

PM1 Interval 2500 gal

Operator Inducement Progress Configuration Reduced Performance

Operator Inducement Regulation Configuration Worldwide

Enabled

46.6° C (116° F)

40° C (104° F)

Disabled

Disabled

Disabled

Disabled

Operator Inducement Emergency Override Enable Status Disabled

Operator Inducement Emergency Override Activation Not Activated

Operator Inducement Emergency Override Mode Configuration Standard

Operator Final Inducement Action Shutdown

Air Inlet Temperature Calibration Value Disabled or Not Installed

System Operating Voltage Configuration 12 V

Backup Timing Sensor Calibration Offset -0.25 Degrees

Primary Timing Sensor Calibration Offset -0.40 Degrees

44 M0068760
Operation Section

Engine Starting

Engine Starting

i02109067

Before Starting Engine

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.

• 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
to the 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.

• 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 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.

• 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.

i06092648

Starting 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.

M0068760 45

Operation Section

Starting the Engine

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. Place the transmission in NEUTRAL. Disengage
the flywheel clutch 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.

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.

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
proper engine oil pressure or fuel pressure is
achieved. Do not apply a load to the engine or
increase engine rpm 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. When the engine is
idled in cold weather, increase the engine rpm to
approximately 1000 to 1200 rpm in order to raise
engine temperature. Do not exceed the
recommended rpm in order to increase the speed of
the warm-up. Limit unnecessary idle time to 10
minutes.

Starting Problems

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

• Low battery charge

• 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).

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.

5. Allow the engine to idle for approximately 3
minutes. Idle the engine until the water
temperature gauge has begun to rise. Check all
gauges during the warm-up period.

NOTICE

46 M0068760
Operation Section

Cold Weather Starting

If the other problems are suspected, perform the
appropriate procedure in order to start the engine.

Problems with the Wiring Harness

Illustration 51 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.

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”.

i06092747

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.

3. Start the engine. If the engine does not start, check
for a diagnostic code and consult your Perkins
distributor.

i04132731

Cold Weather Starting

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.

Starting with Jump Start
Cables

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

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.

M0068760 47

Operation Section

After Starting Engine

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

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
Will Not Crank and Engine Cranks But Will Not Start”
for further information. Make any necessary repairs.
If the engine will not start only due to the condition of
the battery, either charge the battery, or start the
engine by using another battery with jump-start
cables. The condition of the battery can be
rechecked after the engine has been switched OFF.

NOTICE

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

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

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

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

1. Turn the start switch on the stalled engine to the
OFF position. Turn off all the engines accessories.

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

After jump starting, the alternator may not be able to
recharge fully batteries that are severely discharged.
The batteries must be replaced or charged to the
proper 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”.

i05359363

After Starting Engine

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.

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

• Check for fluid or air leaks at idle rpm and at one­half full rpm (no load on the engine) before
operating the engine under load. Operating the
engine at idle and at one-half full rpm with no load
is not possible in some applications.

• Operate the engine at low idle 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.

Extended Idle at Cold Ambient
Temperature

3. Connect one negative end of the jump-start cable

to the negative cable 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.

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”.

The engine may automatically change speeds when
the engine is idling in cold ambient temperatures
(typically less than 0° C (32° F) for extended periods.
The purpose of the automatic speed change is
threefold: to maintain the desired operation of the
NOx reduction system, to maintain the desired
operation of the regeneration system and to keep the
engine coolant warm. The engine speed may rise to
1600 rpm for as long as 20 minutes.

The high exhaust system temperature lamp may
illuminate during extended idling conditions. This
illumination signals that a diesel particulate filter
(DPF) regeneration is in progress. Regenerations
during cold ambient extended idling may only last up
to 10 minutes.

48 M0068760
Operation Section

Engine Operation

Engine Operation

i06603162

Engine Operation

Proper 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.

The time that is needed for the engine to reach
normal operating temperature can be less than the
time taken for a walk-around inspection.

The engine can be operated at the rated rpm after
the engine is started and after the engine reaches
operating temperature. The engine will reach normal
operating temperature sooner during a low engine
speed (rpm) and during a low-power demand. This
procedure is more effective than idling the engine at
no load. The engine should reach operating
temperature in a few minutes.

Avoid excess idling. Excessive idling causes carbon
buildup, engine slobber and, soot loading of the
Diesel Particulate Filter (DPF). These issues are
harmful to the engine.

Gauge readings should be observed and the data
should be recorded frequently whilst 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.

Engine Operation and the
Aftertreatment System

The exhaust gases and hydrocarbon particles from
the engine first pass through the Diesel Oxidation
Catalyst (DOC). Some of the gases and hydrocarbon
particles are oxidized as they pass through the DOC.
The gases then pass through the Diesel Particulate
Filter (DPF). The DPF collects the soot and any ash
that is produced by the combustion in the engine.
During regeneration, the soot is converted into a gas
and the ash remains in the DPF. The gases finally
pass through the Selective Catalytic Reduction
(SCR). Before the gases pass through the SCR,
Diesel Exhaust Fluid (DEF) is injected into the gas
stream. The DEF is controlled by the Pump
Electronic Unit (PEU). The mixtures of DEF and the
exhaust gas pass through the SCR reducing the NOx
in the exhaust emissions.

The engine software will control the amount of DEF
that will be required to keep the exhaust emission
compliant.

This design of DPF will require a service
maintenance interval. Refer to this Operation and
Maintenance Manual, “Maintenance Interval

Schedule” for more information. The DPF can be
expected to function properly for the useful life of the

engine (emissions durability period), as defined by
regulation, subject to prescribed maintenance
requirements being followed.

i06605685

Diesel Particulate Filter
Regeneration

Regeneration

Regeneration is to increase the exhaust temperature
for a given time. The Aftertreatment Regeneration
Device (ARD) creates the heat which makes
regeneration possible. The regeneration process is
used to remove soot from the DPF, and warmup the
Selective Catalyst Reduction (SCR) system. The
DPF traps both soot and ash. The ash is removed
through a manual cleaning process. Refer to
Operation and Maintenance Manual, “Diesel
Particulate Filter - Clean” for more information on the

service of the DPF.

Regeneration Indicators

Regeneration Active – When
illuminated, this indicator shows that

the system is active. This indicator
shows that elevated emission temperatures are
possible. This indicator will turn off when
regeneration is complete.

DPF – This indicator will illuminate to

show that regeneration is required. This

indicator will illuminate when ““Time to
Regen”” is less than a pre-determined amount of
time.

Regeneration Disabled – This indicator

will illuminate to show that regeneration

has been disabled.

Regeneration Switch

Force Regeneration – Press in the top

switch for 2 seconds to begin

regeneration.

Disable Regeneration – Press in the

bottom switch for 2 seconds to disable

regeneration.

Note: If equipped with a rocker style switch, the

MIDDLE position of the regeneration switch is the
default position for automatic regeneration.

M0068760 49

Operation Section

Diesel Particulate Filter Regeneration

Note: If the engine start switch key is cycled or the
“Force Regeneration” switch is pressed for longer
than 2 seconds the system will no longer be disabled.
When the “Force Regeneration” switch is pressed
and “Time to Regen” is less than 8 hours,
regeneration will begin if the machine is at low idle
and is parked.

Note: If the engine start switch key is cycled whilst
the regeneration system is disabled via the “Disable
Regeneration” switch, press and hold the “Disable
Regeneration” switch for 2 seconds to reinitiate.

Modes of Regeneration

Automatic: The Electronic Control Module (ECM)

uses multiple inputs from the engine and the machine
to determine the best time to perform automatic
regeneration. Automatic regenerations can take
place throughout the operating cycle of the engine.
The regeneration active indicator will be illuminated
when regeneration is being performed. Interruptions
of the regeneration are acceptable. If regeneration is
in progress and the regeneration needs to be
stopped, it is permissible to press the “Disable
Regeneration” switch.

Note: Automatic adjustments of engine speed may
be noticed during regenerations. If regeneration is
taking place and the engine is taken to low idle, the
engine speed may remain elevated to maintain the
regeneration.

Note: If the machine returns to work whilst automatic
regeneration is active, the regeneration may be
stopped. The ECM will continue to monitor inputs to
determine the best time to restart the regeneration.

Disabled: When the regeneration system is in
disabled mode, automatic regenerations will not be
performed. The DPF indicator will illuminate if manual
regeneration is required. The “Time to Regen”
displayed on the performance screen will indicate
that the time until the next regeneration will be
required. However, the DPF indicator may illuminate
with time remaining on the display. When the DPF
indicator illuminates, the operator must perform
manual regeneration.

Regeneration Triggers

Regeneration may be required for the following
reasons:

Soot: The DPF will collect soot produced by the
engine. Automatic regeneration will become active to
reduce soot level.

Start-Up Regeneration: Start-up regeneration is
initiated by the ECM after a cold engine start. This
regeneration is performed to heat the system to a
required temperature for Diesel Exhaust Fluid (DEF)
dosing to begin.

SCR Maintenance: Regeneration is performed to
maintain the SCR system.

ARD Maintenance: Regeneration is performed to
maintain the CRS system.

Regeneration System Warning
Indicators

Manual: Manual regeneration is initiated by pressing

the “Force Regeneration” switch. Manual
regeneration will only be allowed if the “Time to
Regen” is less than 8 hours. If the “Force
Regeneration” switch is pressed before “Time to
Regen” is less than 8 hours, then “Regen not
Required” will be displayed. The machine must be
stationary, the parking brake must be applied, and
the engine must be at low idle to perform manual
regeneration.

Illustration 52 g02117258

The DPF Indicator will illuminate solid when
regeneration is required. Regeneration should be

performed as soon as possible.

Note: In some situations, the DPF indicator may stay
illuminated after regeneration ends. The illuminated
DPF indicator indicates that complete regeneration
has not been performed. Complete regeneration is
when the soot has been depleted or all the criteria for
one of the other regeneration types have been met. If
the DPF indicator stays illuminated, perform,
regeneration without interruption. The DPF indicator
will shut off when regeneration is complete.

50 M0068760
Operation Section

Engaging the Driven Equipment

If the soot load is above a threshold or “Time to
Regen” is 0 hours, then regeneration is required. The

DPF indicator will illuminate and flash slowly. Engine
power will be slightly derated. If the machine
continues to operate without regeneration, derate will
eventually reach 100%. Stop the machine and apply
the parking brake. With the engine at low idle, initiate
manual regeneration.

Illustration 53 g03679876

Once the amount of soot collected in the DPF has
reached a threshold or “Time to Regen” has been at

0 hours for a pre-determined time, the DPF indicator
will illuminate and flash at a fast rate. A red stop lamp
will illuminate solid.

10 minutes after the illumination of the DPF indicator
and red stop lamp the engine will Shut down. The

engine can be restarted by cycling the engine start
switch key. The engine will return to the previous
derate state before shutdown.

3. Ensure that the ranges of the gauges are normal

when the engine is operating at one-half of the
rated rpm. Ensure that all gauges operate
properly.

4. Increase the engine rpm to the rated rpm. Always

increase the engine rpm to the rated rpm before
the load is applied.

5. Apply the load. Begin operating the engine at low

load. Check the gauges and equipment for proper
operation. After normal oil pressure is reached and
the temperature gauge begins to move, the engine
may be operated at full load. Check the gauges
and equipment frequently when the engine is
operated under load.

Extended operation at low idle or at 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.

i04018232

Fuel Conservation Practices

Once the amount of soot collected reaches a
threshold level or 6.4 hours of run time has passed

since the red stop lamp was illuminated without
successful regeneration, the engine will have a 100%
derate.

Once the amount of soot collected reaches a critical
threshold level, the regeneration will be locked out.

Now, regeneration can only be performed by using
electronic service tool. The engine may be restarted,
but will only run for 3 minutes before shutting down
again.

i04038637

Engaging the Driven
Equipment

1. Operate the engine at one-half of the rated rpm,

when possible.

2. Engage the driven equipment without a load on the
equipment, when possible.

Interrupted starts put excessive stress on the drive
train. Interrupted starts also waste fuel. To get the
driven equipment in motion, engage the clutch
smoothly with no load on the equipment. This
method should produce a start that is smooth and
easy. The engine rpm should not increase and the
clutch should not slip.

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 turbocharger is operating
correctly. For more information refer to this
Operation and Maintenance Manual ,
“Turbocharger - Inspect”

• Maintain a good electrical system.

M0068760 51

Operation Section

Fuel Conservation Practices

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

• The belt should be in good condition. Refer to the
Systems Operation, Testing and Adjusting, “V-Belt
Test” for further information.

• Ensure that all of the connections of the hoses are
tight. The connections should not leak.

• Ensure that the driven equipment is in good
working order.

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

52 M0068760
Operation Section

Engine Stopping

Engine Stopping

i05798719

Stopping the Engine

NOTICE

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

See the following stopping procedure, to allow the
engine to cool, and to prevent excessive tempera­tures in the turbocharger center housing, which could
cause oil coking problems.

1. While the machine is stopped, run the engine for 5
minutes at low idle. Idling the engine allows hot
areas of the engine to cool gradually.

Note: If the “Regen Active” indicator is illuminated,
do not shut off the engine. Refer to Operation and
Maintenance Manual, “Monitoring System” for more
information on indicators. (if equipped)

2. Turn the engine start switch to the OFF position
and remove the key.

Note: The engine may delay before completely
shutting down. Delayed engine shutdowns aid in
cooling the engine and after-treatment (if equipped)
components.

Delayed Engine Shutdown (If
Enabled)

Leaving the machine unattended when the engine
is running may result in personal injury or death.
Before leaving the machine operator station, neu­tralize the travel controls, lower the work tools to

the ground and deactivate all work tools, and
place the lever for the hydraulic lockout control
in the LOCKED position.

Note: Leaving the engine unattended while running

may result in property damage in the event of a
malfunction.

Turn the engine start switch to the OFF position.

Delayed Engine Shutdown – The
delayed engine shutdown indicator will
illuminate or the following text will be

displayed, ENGINE COOLDOWN ACTIVE.

Delayed engine shutdown will run whenever the
exhaust temperature is above a threshold at engine
shutdown. Delayed engine shutdown will run for a
minimum of 76 seconds and will continue to run until

the engine and system components are cooled. The
default maximum run time is 7 minutes.

Note: An authorized dealer can change the
maximum run time value up to 30 minutes, but the
default setting is 7 minutes.

Note: To override delayed engine shutdown and stop
the engine, turn the engine start switch to the STOP
position. Overriding delayed engine shutdown may
reduce engine and system component life. A warning
message and/or audible alarm will be initiated and a
fault code will be logged for improper engine
shutdown.

The Delayed Engine Shutdown allows the engine to
run for a time after the engine start switch key is
turned to the OFF position to cool the engine and
system components. The engine start switch key
may be removed.

Note: The DEF purge process will run for 2 minutes
once the engine is shut down and must complete.
The purge process may occur during delayed engine
shutdown. Do not turn off battery disconnect switch
during the purge process. Do not turn off the battery
power disconnect switch until the battery disconnect
switch indicator lamp has turned off. If the purge
process does not complete, a diagnostic code will
become active.

Note: There may be regulations that define the
requirements for the operator and/or support
personnel to be present when the engine is running.

M0068760 53

Operation Section

Manual Stop Procedure

i01465494

After Stopping Engine

Note: Before you check the engine oil, do not

operate the engine for at least 10 minutes 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

Illustration 54 g02362719

Note: At any time during a delayed engine shutdown,
the engine start switch may be turned to the ON
position. The engine may be placed back into
service.

i05812522

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”.

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

Manual Stop Procedure

NOTICE

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.

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.

• 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.

1. Remove the load from the engine so that the
engine has no more than 30% power.

2. Run the engine at the programmed low idle speed
for at least 3 minutes.

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

54 M0068760
Operation Section

Cold Weather Operation

Cold Weather Operation

i05203509

Radiator Restrictions

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. Reducing air flow can
increase surface temperatures during an
aftertreatment regeneration and could affect
component reliability.

Reducing air flow can increase surface temperatures
during an aftertreatment regeneration and could
affect component reliability.

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

2

i05849931

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 is expected to see in the operation.

Following properties are used to define fuels low
temperature capability:

• Cloud point

• Pour point

• Cold Filter Plugging Point (CFPP)

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 Cetane
number. Detail and requirements of this property are
given in this Operation and Maintenance Manual,
“Fluid Recommendations”.

Note: Only use grades of fuel that are recommended
by Perkins. Refer to this Operation and Maintenance
Manual, “Fluid Recommendations”.

M0068760

55

Operation Section

Fuel Related Components in Cold Weather

i06093465

Fuel Related Components in
Cold Weather

Fuel Tanks

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

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

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

supply pipe.

Some fuel tanks use supply lines that take fuel
directly 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

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 your
Perkins distributor .

• 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).

56 M0068760
Maintenance Section

Refill Capacities

Maintenance Section

Refill Capacities

i05810173

Fluid Recommendations

(Diesel Exhaust Fluid (DEF))

General Information

Diesel Exhaust Fluid (DEF) is a liquid that is injected
into the aftertreatment system before Selective
Catalytic Reduction (SCR). This system of injecting
the DEF into the exhaust will reactor in the SCR

system. The Nitrogen Oxide (NOx) molecules in the
exhaust are converted to elemental nitrogen and
water. This conversion will reduce the emission of the

engine.

Specification

DEF that is used in Perkins engines must meet the
ISO specification 22241-1 for quality. The ISO
specification 22241-1 requirements are met by many
brands of DEF, including those that carry the AdBlue
or API certification."

The document series ISO standard 22241 will give
information on quality requirements, test methods,
handling, transportation, storage, and refilling
interface.

DEF Quality

The quality of DEF can be measured by using a
refractometer. The DEF must comply with ISO
standard 22241-1 with the urea solution of 32.5

percent. Perkins offer a T400195 Refractometer for
checking the concentration of the DEF.

Cleanliness

Contaminants can degrade the quality and life of
DEF. Filtering DEF is recommended when dispensed
into the DEF tank. Filters should be compatible with
DEF and should be used exclusively with DEF.
Check with the filter supplier to confirm compatibility
with DEF before using. Mesh-type filters using
compatible metals, such as stainless steel, are
recommended. Paper (cellulose) media and some
synthetic filter media are not recommended because
of degradation during use.

Care should be taken when dispensing DEF. Spills
should be cleaned immediately. Machine or engine
surfaces should be wiped clean and rinsed with
water. Caution should be used when dispensing DEF
near an engine that has recently been running.
Spilling DEF onto hot components will cause harmful

vapors.

Storage

Do not store DEF in direct sunlight.

Table 5

Storage Temperature Expected DEF Life

Below 25° C (77° F) 18 months

25° C (77° F) to 30° C (86° F) 12 months

Spillage

Care should be taken when dispensing DEF. Spills
should be cleaned immediately. All surfaces should
be wiped clean and rinsed with water.

DEF that has been split will crystallize when the
water within the liquid evaporates. Spilt DEF will
attack paint and metal. If DEF is split, wash the area
with water.

Caution should be used when dispensing DEF near
an engine that has recently been running. Spilling
DEF onto hot components may cause the release of
ammonia vapors. Do not breathe ammonia vapors.
Do not clean up any spills with bleach.

Filling the DEF Tank

The fill cap on the DEF tank must be colored blue.
The DEF level is important, allowing the DEF tank to
run dry or operate at a low level can affect the engine
operation. Because of the corrosive nature of DEF,
the correct materials must be used when filling a DEF
tank.

30° C (86° F) to 35° C (95° F) 6 months

Above 35° C (95° F) test quality before use

Perkins recommend that all DEF taken from storage
should be checked to ensure the DEF meets ISO

standard 22241-1.

Materials compatibility

DEF is corrosive. Due to the corrosion caused, DEF
must be stored in tanks constructed of approved

materials. Recommended storage materials:

Stainless Steels:

• 304 (S30400)

• 304L (S30403)

• 316 (S31600)

• 316L (S31603)

Alloys and metals:

• Chromium Nickel (CrNi)

M0068760

• Chromium Nickel Molybdenum (CrNiMo)

• Titanium

Non-metallic materials:

• Polyethylene

• Polypropylene

• Polyisobutylene

• Teflon (PFA)

• Polyfluoroethylene (PFE)

57

Maintenance Section

Fluid Recommendations

• Polyvinylidene fluoride (PVDF)

• Polytetrafluoroethylene (PTFE)

Materials NOT compatible with DEF solutions include
Aluminum, Magnesium, Zinc, Nickel coatings, Silver
and Carbon steel and Solders containing any of the
above. Unexpected reactions may occur if DEF
solutions come in contact with any non-compatible
material or unknown materials.

i06103357

Fluid Recommendations

General Lubricant Information

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

• API American Petroleum Institute

• SAE Society Of Automotive Engineers Inc.

• ACEA Association des Constructers
European Automobiles.

• ECF-3 Engine Crankcase Fluid

Illustration 55 g01987816

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).

Engine Oil

Commercial Oils

NOTICE

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

Table 6

Oil Specification

Licensing

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

API CJ-4
ACEA E9
ECF-3

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

• 0.1 percent maximum sulfated ash

• 0.12 percent maximum phosphorous

• 0. 4 percent maximum sulfur

58 M0068760
Maintenance Section

Fluid Recommendations

The chemical limits were developed in order to
maintain the expected life of the engine
aftertreatment system. The performance of the
engine aftertreatment system can be adversely
affected if oil that is not specified in table 6 is used.

The life of your Aftertreatment system is defined by
the accumulation of ash on the surface of the filter.

Ash is the inert part of the particulate matter. The
system is designed in order to collect this particulate
matter. There is a very small percentage of
particulate matter that is left behind as the soot is
burnt. This matter will eventually block the filter,
causing loss of performance and increased fuel
consumption. Most of the ash comes from the engine
oil which is gradually consumed during normal
operation. This ash is passes through the exhaust. To
meet the designed life of the product, the use of the
appropriate engine oil is essential. The oil
specification that is listed in table 6 has low ash

content.

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

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

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

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

Refer to illustration 56 (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.

Illustration 56 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, depending on the parasitic load and other
factors. Cold soaked starts occur when the engine
has not been operated for a period of time. This
interval will allow the oil to become more viscous due

to cooler ambient temperatures.

Aftermarket Oil Additives

Perkins does not recommend the use of aftermarket
additives in oil. It is not necessary to use aftermarket

additives in order to achieve the engines maximum
service life or rated performance. Fully formulated,
finished oils consist of base oils and of commercial

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

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 56 in order to find the correct oil
viscosity grade for your engine.

M0068760 59

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
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

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.

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.

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 7
.

Table 7

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

60 M0068760
Maintenance Section

Fluid Recommendations

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:

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 8 and refer to table 9 .

Table 8

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 9

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.

• Formation of gel compounds

• Reduction of heat transfer

• Leakage of the water pump seal

• Plugging of radiators, coolers, and small passages

Glycol

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

• Boiling

• Freezing

• Cavitation of the water pump

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

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

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

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

NOTICE

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

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

M0068760 61

Maintenance Section

Fluid Recommendations

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 10

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

3000 Service Hours or Two Year

3000 Service Hours or One Year

Service Life

6,000 Service Hours or Three

(1)

Years

ELC

Perkins provides ELC for use in the following
applications:

• Heavy-duty spark ignited gas engines

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).

• 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.

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

ELC Cooling System Cleaning

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.

62 M0068760
Maintenance Section

Fluid Recommendations

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.

• 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.

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.

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 effective­ness of the ELC and shortens the ELC service life.

Use only Perkins Products for premixed or concen­trate coolants. Failure to follow these recommenda-

tions 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:

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 11 to determine the
amount of SCA that is required when the cooling
system is initially filled.

Table 11

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.

X is the amount of SCA that is required.

M0068760 63

Maintenance Section

Fluid Recommendations

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) × 0.045 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.

Use the equation that is in Table 13 to determine the
amount of SCA that is required, if necessary:

Table 13

Equation For Adding The SCA To The Heavy-Duty Coolant

V is the total volume of the cooling system.

For Maintenance

V × 0.014 = X

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

i06603367

Fluid Recommendations

(General Fuel Information)

• 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

• ULSD Ultra Low Sulfur Diesel

• RME Rape Methyl Ester

• SME Soy Methyl Ester

• EPA Environmental Protection Agency of
the United States

• PPM Parts Per Million

• DPF Diesel Particulate Filter

X is the amount of SCA that is required.

Table 14 is an example for using the equation that is
in Table 13 .

Table 14

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

that is Required

Amount of SCA

(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.

General Information

NOTICE

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.

NOTICE

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

Diesel Fuel Requirements

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

specifications that are published by governments and
technological societies.

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

64 M0068760
Maintenance Section

General Fuel Information

Satisfactory engine performance depends 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
the table 15 .

The footnotes are of the key part Perkins Specifica-

NOTICE

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

Table 15

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%
Bottoms

Cetane Number

Cloud Point °C The cloud point must not

Copper Strip Corrosion

Density at 15 °C (59 °F)

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

Flash Point °C legal limit D93 “ISO”2719

Thermal Stability

(2)

%Weight 0.35% maximum D524 “ISO”4262

-

-

3

(3)

kg/m

-

40 minimum D613/D6890 “ISO”5165

exceed the lowest expected
ambient temperature.

No. 3 maximum D130 “ISO”2160

801 minimum and 876
maximum

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

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

D2500 “ISO”3015

No equivalent test “ISO 3675”“ISO 12185”

D86 “ISO”3405

D6468 No equivalent test

(1)

Pour Point °C 6 °C (42.8 °F) minimum be-

low ambient temperature

(1)

Sulfur

Kinematic Viscosity

Water and sediment % weight 0.1% maximum D1796 “ISO”3734

Water % weight 0.1% maximum D1744 No equivalent test

Sediment % weight 0.05% maximum D473 “ISO”3735

%mass 0.0015 D5453/D26222 “ISO 20846”“ISO 20884”

(4)

mm2/s (cSt) The viscosity of the fuel that

is delivered to the fuel injec­tion pump. “1.4 minimum/

4.5 maximum”

D97 “ISO”3016

D445 “ISO”3405

(continued)

M0068760 65

Maintenance Section

General Fuel Information

(Table 15, contd)

Gums and Resins

Lubricity correctedwear
scar diameter at 60 °C
(140 °F).

(1)

(2)

(3)

(4)

(5)

(6)

(6)

This specification includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to
“ASTM D5453”, “ASTM D2622”, or “ISO 20846, ISO 20884” test methods.
A fuel with a higher cetane number is recommended to operate at a higher altitude or in cold weather.
“Via standards tables, the equivalent API gravity for the minimum density of 801 kg / m3(kilograms per cubic meter) is 45 and for the maxi­mum density of 876 kg / m
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 in order to lower the viscosity to “1.4 cSt” at the fuel injection
pump.
Follow the test conditions and procedures for gasoline (motor).
The lubricity of a fuel is a concern with ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or ASTM D6079 High
Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum 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.

(5)

mg/100mL 10 mg per 100 mL

mm

3

is 30”.

maximum

0.52 maximum D6079 “ISO”12156-1

D381 “ISO”6246

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

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

NOTICE

Operating with fuels that do not meet the Perkins rec­ommendations can cause the following effects: Start­ing difficulty, reduced fuel filter service life, poor
combustion, deposits in the fuel injectors, signifi­cantly reduce service life of the fuel system, deposits
in the combustion chamber and reduced service life

of the engine.

Illustration 57 g02157153

Illustration 57 is a representation of the label that will
be installed next to the fuel filler cap on the fuel tank
of the application.

The fuel specifications that are listed in the table 16
are released as acceptable to use on all 2806F series

NOTICE

of engine.
The Perkins 2806F series of diesel engine must be
operated using Ultra Low Sulfur Diesel. The sulphur
content of this fuel must be lower than 15 PPM. This

fuel complies with the emissions regulations that are
prescribed by the Environmental Protection Agency
of the United States.

Table 16

Acceptable Fuel Specification for the 2806F Series of Engines

Fuel Specification Comments

(1)

EN590 European Automotive Diesel Fuel (DERV)

(continued)

66 M0068760
Maintenance Section

General Fuel Information

(Table 16, contd)

“ASTM D975 GRADE 1D S15” “North American Light Distillate Diesel fuel with less than 15 PPM sul-

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

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

fur level”

than 15 PPM sulfur level”

the section “Lubricity”.

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

(1)

All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel.

Diesel Fuel Characteristics

10 PPM sulfur level”

Perkins recommends kinematic viscosities of 1.4 and

4.5 mm2/sec that is delivered to the fuel injection

Cetane Number

pump. If a fuel with a low viscosity is used, cooling of

the fuel may be required to maintain 1.4 cSt or
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

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.
for fuels against proportions of cetane and

heptamethylnonane in the standard CFR engine.
Refer to “ISO 5165” for the test method.

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 fuel with higher cetane number is
recommended for operations at high altitudes or in
cold-weather operations.

Density

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

from a heat output given injected volume of fuel. This

parameter is quoted in the following kg/m

(59 °F).

Perkins recommends a density of 841 kg/m

3

at 15 °C

3

to

obtain the correct power output. Lighter fuels are
Fuel with a low cetane number can be the root cause
of problems during a cold start.

Viscosity

acceptable but these fuels will not produce the rated

power.

Sulfur

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 extremely cold temperatures and
extremely hot temperatures. If the kinematic viscosity
of the fuel is lower than “1.4 cSt” at the fuel injection
pump, damage to the fuel injection pump can occur.
This damage can be excessive scuffing and seizure.
Low viscosity may lead to difficult hot restarting,
stalling, and loss of performance. High viscosity may
result in seizure of the pump.

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.

Perkins 2806F series diesel engines have been

designed to operate only with ULSD. By using the

test methods “ASTM D5453, ASTM D2622, or ISO

20846 ISO 20884”, the content of sulfur in ULSD fuel

must be below 15 PPM (mg/kg) or 0.0015% mass.

NOTICE

Use of diesel fuel with higher than 15 PPM sulphur

limit in these engines will harm or permanently dam-

age emissions control systems and/or shorten their

service interval.

M0068760 67

Maintenance Section

General Fuel Information

Lubricity

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

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

The lubricity has particular significance to the current
ultra low sulfur fuel, and low aromatic fossil fuels.

These fuels are made to meet stringent exhaust
emissions.

The lubricity of these fuels must not exceed wear
scar diameter of 0.52 mm (0.0205 inch). The fuel
lubricity test must be performed on an HFRR,
operated at 60 °C (140 °F). Refer to “ISO 12156-1”.

NOTICE

The fuels system has been qualified with fuel having
lubricity up to 0.52 mm (0.0205 inch) wear scar diam­eter as tested by “ISO 12156-1”. Fuel with higher
wear scar diameter than 0.52 mm (0.0205 inch) will
lead to reduced service life and premature failure of
the fuel system.

Fuel additives can enhance the lubricity of a fuel.
Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier
can make recommendations for additives to use, and

for the proper level of treatment.

Distillation

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

hydrocarbons can affect the characteristics of
combustion.

Recommendation for Biodiesel and
Using B20

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 feedstocks. The most commonly
available biodiesel in Europe is Rape Methyl Ester
(RME). 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 solidify 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 generally referred

to as B100 biodiesel or neat biodiesel.

Biodiesel can be blended with distillate diesel fuel.

The blends can be used as fuel. The most commonly

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

D975-09a” 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 the latest

“EN14214 or ASTM D6751” (in the USA). The

biodiesel can only be blended in mixture of up to 20%

by volume in acceptable mineral diesel fuel meeting

latest edition of “EN590 or ASTM D975 S15”

designation.

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.

68 M0068760
Maintenance Section

General Fuel Information

Engine Service Requirements

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
recommend that after the initial usage of B20
biodiesel blended fuel the fuel filters must be

replaced at 50 hours.

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 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
sump. The long-term effect of biodiesel
concentration in crankcase oil is currently
unknown.

• Perkins recommend 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

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. These
deposits can cause a loss in power due to restricted
or modified fuel injection or cause other functional
issues associated with these deposits.

Note: Perkins T40-0012 Fuel Cleaner is most
effective in cleaning and preventing the formation of
deposits. Perkins Diesel Fuel Conditioner helps to
limit deposit issues by improving the stability of
biodiesel and biodiesel blends. For more information
refer to “Perkins Diesel Fuel System Cleaner, and
Perkins”.

Biodiesel fuel contains metal contaminants (sodium,

potassium, calcium, and/or magnesium) that form

ash products upon combustion in the diesel engine.

The ash can have an impact on the life and

performance of aftertreatment emissions control

devices and can accumulate in DPF. The ash

accumulation may cause the need for more frequent

ash service intervals and cause loss of performance

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, it is strongly recommended that engines with

limited operational time either not use B20 biodiesel

blends or, whilst 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.

Perkins strongly recommended 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.

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 anti-microbial

additive.

Water accelerates microbial contamination and

growth. When biodiesel is compared to distillate

fuels, water is naturally more likely to exist in the

biodiesel. It is therefore essential to check frequently

and if necessary, drain the water separator.

Materials such as brass, bronze, copper, lead, tin,

and zinc accelerate the oxidation process of the

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” for more information of the physical

properties of the fuel.

M0068760 69

Maintenance Section

Refill Capacities and Recommendations

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

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

Aftermarket Fuel Additives

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

potential damage to the fuel system or the engine.
Your fuel supplier or the fuel manufacturer will add
the appropriate supplemental diesel fuel additives.

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

Note: Some anti-corrosion additives can lead to
injector fouling, this fouling can cause the injector to
operate incorrectly.

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 15 .

Note: Perkins fuel cleaner is compatible with existing

and U.S. EPA Tier 4 nonroad certified diesel engine

emission control catalysts and particulate filters.

Perkins fuel system cleaner contains less than 15

ppm of sulfur and is acceptable for use with ULSD

fuel.

i06611108

Refill Capacities and

Recommendations

Refill Capacities

Lubricant Refill Capacity

Perkins Diesel Fuel System Cleaner

Perkins T40-0012 Fuel Cleaner is the only fuel
cleaner that is recommended by Perkins.

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

use of the fuel is to remove deposits within the fuel
system that is created with the use of biodiesel. For
more information on the use of biodiesel and

biodiesel blends refer to “Recommendation for
Biodiesel and Using B20”.

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.

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

Illustration 58 g02300456

Standard pan

Illustration 59 g02300473

Center pan

Illustration 60 g02300474

Deep pan

70 M0068760
Maintenance Section

Refill Capacities and Recommendations

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 17

2806F Industrial Engine

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
18 should be completed by the customer for the
maintenance of the cooling system.

Table 18

Approximate Capacity of the Cooling System

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.

M0068760 71

Maintenance Section

Maintenance Recommendations

Maintenance
Recommendations

i02909163

System Pressure Release

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.

i05359716

Welding on Engines with

Electronic Controls

NOTICE

Because the strength of the frame may decrease,

some manufacturers do not recommend welding onto

a chassis frame or rail. Consult the OEM of the equip-

ment or your Perkins dealer regarding welding on a

chassis frame or rail.

Proper welding procedures are necessary in order to

avoid damage to the engines ECM, sensors, and

associated components. When possible, remove the

component from the unit and then weld the

component. If removal of the component is not

possible, the following procedure must be followed

when you weld on a unit equipped with an Electronic

Engine. The following procedure is considered to be

the safest procedure to weld on a component. This

procedure should provide a minimum risk of damage

to electronic components.

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, hy-

draulic components, electrical components, and oth-

er components.

Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close

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

sibility 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:

72 M0068760
Maintenance Section

Welding on Engines with Electronic Controls

• Electronic components for the driven
equipment

• ECM

• Sensors

• Electric operated fuel pump

• Electronically controlled valves

• Relays

• Aftertreatment ID module

Do not use electrical components (ECM or ECM sen-

NOTICE

sors) or electronic component grounding points for
grounding the welder.

Illustration 61 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

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 electrical/electronic
components 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.

M0068760 73

Maintenance Section

Severe Service Application

7. Use standard welding practices to weld the
materials.

i05196263

Severe Service Application

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:

• 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 your
Perkins dealer or your Perkins distributor in order to
determine if the engine is operating within the defined
parameters.

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

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, it is not possible to
identify all of the factors which can contribute to
severe service operation. Consult your Perkins
dealer or your Perkins distributor for the unique
maintenance that is necessary for the engine.

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
environments 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.

74 M0068760
Maintenance Section

Maintenance Interval Schedule

i06606839

Maintenance Interval Schedule

When Required

“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . . 78

“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 78

“ Battery or Battery Cable - Disconnect” . . . . . . . . . 79

“ DEF Filler Screen - Clean” . . . . . . . . . . . . . . . . . . . . .

“ Diesel Exhaust Fluid - Fill”. . . . . . . . . . . . . . . . . . . 85

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

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . . 93

“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 96

“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Daily

“ Air Tank Moisture and Sediment - Drain” . . . . . . . 78

“ Cooling System Coolant Level - Check”. . . . . . . . 83

“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . . 87

“ Engine Air Cleaner Service Indicator - Inspect” . . 89

“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 89

“ Fuel System Primary Filter/Water Separator -

Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

“ Hoses and Clamps - Inspect/Replace”. . . . . . . . . 97

Every 500 Service Hours or 3
Months

“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 80

Every 2000 Service Hours

“ Air Shutoff - Test” . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Every 2500 Service Hours

“ Electronic Unit Injector - Inspect/Adjust” . . . . . . . 87

“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . 92

Every 3000 Service Hours or 3
Years

“ Cooling System Coolant (DEAC) - Change” . . . . 80

Every 4000 Service Hours

“ Air Compressor - Check”. . . . . . . . . . . . . . . . . . . . 77

“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 89

“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 98

Every 5000 Service Hours

“ ARD Spark Plug - Clean”. . . . . . . . . . . . . . . . . . . . 76

“ Diesel Exhaust Fluid Filter - Replace” . . . . . . . . . 85

“ Diesel Particulate Filter - Clean” . . . . . . . . . . . . . . 86

“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 98

Every 250 Service Hours

“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 90

“Grounding Stud - Inspect/Clean/Tighten” . . . . . . . 96

Every 500 Service Hours

“ Battery Electrolyte Level - Check” . . . . . . . . . . . . 79

“ Cooling System Supplemental Coolant Additive

(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . 91

“ Fuel System Primary Filter (Water Separator)

Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 93

“ Fuel System Secondary Filter - Replace”. . . . . . . 95

M0068760

“ Injector (Diesel Exhaust Fluid) - Replace” . . . . . 100

Every 6000 Service Hours or 3
Years

“ Cooling System Coolant Extender (ELC) -

Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Every 10 000 Service Hours

“ DEF Manifold Filters - Replace” . . . . . . . . . . . . . 100

Every 12 000 Service Hours or 6
Years

“ Cooling System Coolant (ELC) - Change” . . . . . . 82

Every 760 000 L (200 000 US gal) of
Fuel or 10 000 Service Hours

75

Maintenance Section

Maintenance Interval Schedule

“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . . 98

76 M0068760
Maintenance Section

ARD Spark Plug - Clean

i06615956

ARD Spark Plug - Clean

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.

NOTICE

If the engine is running or the key is in the ON posi­tion the Aftertreatment Regeneration Device (ARD)
plug will continue to fire. Turn the key to the OFF po­sition before servicing the ARD plug.

Removing the Spark Plug

2. Debris may have collected in the spark plug well.

Thoroughly remove any debris. Use compressed
air. The maximum air pressure for cleaning
purposes must be below 205 kPa (30 psi). Ensure
that the area around the spark plug is clean and
free of dirt and debris.

3. Use a 22 mm (0.86 inch)22mm spark plug socket

and a breaker bar to loosen the spark plug. After
the spark plug has been loosened, use the spark
plug socket to remove the spark plug by hand to
detect problems with the threads. After the spark
plug has been removed, inspect the used spark
plug and the gasket.

4. After removing the spark plug, clean the ground

probe inside the ARD combustion head by running
a T400005 Plug Bore Brush through the hole in
the ARD combustion head. This tool scrapes
debris from the seat and from the threads. Run the
brush through the hole several times.

Note: The spark plug may be damaged if the spark
plug is dropped. Do not install a spark plug that has
been dropped or a spark plug that is damaged.

5. Carefully clean the spark plug using a nonmetallic

cleaning pad. If the probe appears to be bent,
replace the spark plug. Do not use a thread tap. A
thread tap will remove metal unnecessarily. The
threads could be stripped and the combustion
group could be damaged.

Illustration 62 g06046854

Typical example

(1) Spark plug
(2) Wiring harness

1. Remove wire harness (2) from spark plug (1).

Installing the Spark Plug

Note: Do not use anti-seize compound on the spark

plug. Most of the heat is transferred through the
threads and the seat area of the spark plug. Contact
of the metal surfaces must be maintained to provide
the heat transfer that is required.

1. Ensure that the spark plug is clean and free of dirt

and oil.

NOTICE

Do not overtighten the spark plug. The shell can be
cracked and the gasket can be deformed. The metal
can deform and the gasket can be damaged. The
shell can be stretched. This will loosen the seal that

is between the shell and the insulator, allowing com­bustion pressure to blow past the seal. Serious dam­age to the engine can occur.

Use the proper torque.

2. Install the spark plug (1) by hand until the spark

plug contacts the ARD. Tighten the spark plug to a
torque of 47 N·m (34 lb ft)

M0068760

77

Maintenance Section

Air Compressor - Check

3. Connect the wiring harness (2).

i06111571

Air Compressor - Check

(If Equipped)

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

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.

i06111591

Air Shutoff - Test

To ensure that the air shutoff valve always shuts
down when the engine ingests gaseous fumes,
perform the test below at each oil change. A test
failure can indicate wear in the block off plate to valve
body interface and/or the bearing system.

1. Place engine at low idle speed. Ensure all

accessories that are normally used for the
application are in use, like a fan, or power takeoffs.

Illustration 63 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.

2. Actuate the air shutoff manually. On electrical

operator air shutoffs, utilize an applicable power
supply or jumper cables from the battery to
energize the air shut-off solenoid. Ensure that the
solenoid receives only a momentary signal to
prevent overheating. On hydraulic operator air
shutoffs, found on some hazardous location units,
actuate by pulling the emergency stop handle.

3. Ensure that air shutoff was actuated and that the

engine comes to a complete stop.

Note: As every application has different parasitic
loads and inertia, the duration for the problem to
occur cannot be specified. However, if the engine
stumbles or attempts to continue running, these
symptoms may be an indication that worn
components may need replacement.

NOTICE

Actuating the air shutoff valve may result in oil leak­age past the shaft seal in some cases. Repeated ac­tuation of the air shutoff valve during loaded
operation of the engine can result in mechanical
damage to the turbocharger and reduce turbocharger
life.

78 M0068760
Maintenance Section

Air Tank Moisture and Sediment - Drain

i00847451

Air Tank Moisture and
Sediment - Drain

(If Equipped)

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

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

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.

i01878164

Battery - Replace

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.

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

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

• A recycling facility

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.

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.

M0068760 79

Maintenance Section

Battery Electrolyte Level - Check

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

i02747977

Battery Electrolyte Level ­Check

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

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

face shield and protective clothing when 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.

i05424317

Battery or Battery Cable ­Disconnect

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.

Note: After the engine has stopped, allow 2 minutes
in order for the diesel exhaust fluid lines to be purged
before disconnecting the power.

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.

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.

80 M0068760
Maintenance Section

Belts - Inspect/Adjust/Replace

i06615861

Belts - Inspect/Adjust/Replace

• 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 (2) 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.

i06606846

Cooling System Coolant
(DEAC) - Change

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

Illustration 64 g06046748

Typical example

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.

• 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.

M0068760 81

Maintenance Section

Cooling System Coolant (DEAC) - Change

Illustration 65 g02351659

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

Drain

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 and

operate the engine, ensure that the thermostat
opens. Stop the engine and allow the engine to
cool.

4. Drain the cooling system.

5. Fill the cooling system with clean water and

operate the engine until the engine is warmed to
82 °C (180 °F).

6. Stop the engine and allow the engine to cool. Drain

the cooling system.

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.

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 to purge the air from the cavities
of the engine block. Stop the engine.

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.

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.

82 M0068760
Maintenance Section

Cooling System Coolant (ELC) - Change

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

i06606848

Cooling System Coolant (ELC)

- Change

Perkins ELC must be using with an extender in order

NOTICE

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.

Illustration 66 g02351659

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 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 to

remove any debris.

2. Close the drain valve.

M0068760 83

Maintenance Section

Cooling System Coolant Extender (ELC) - Add

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 °C to 66 °C
(120 °F to 150 °F).

5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly 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.

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

i06606850

Cooling System Coolant
Extender (ELC) - Add

For Perkins ELC to achieve 12000 hours an extender
must be added at 6000 hours. For a suitable
extender, contact your Perkins distributor.

i06606851

Cooling System Coolant Level

- Check

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

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 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.

Illustration 67 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 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.

84 M0068760
Maintenance Section

Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Use a Coolant Conditioner Test Kit in order to check
the concentration of the SCA.

Add the SCA, If Necessary

Illustration 68 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.

i03644948

Cooling System Supplemental
Coolant Additive (SCA) - Test/
Add

Do not exceed the recommended amount of supple-

NOTICE

mental coolant additive concentration. Excessive
supplemental coolant additive concentration can form

deposits on the higher temperature surfaces of the
cooling system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could cause

cracking of the cylinder head and other high tempera­ture components. Excessive supplemental coolant
additive concentration could also result in radiator

tube blockage, overheating, and/or accelerated water
pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if
equipped) at the same time. The use of those addi­tives together could result in supplemental coolant
additive concentration exceeding the recommended
maximum.

Pressurized System: Hot coolant can cause seri­ous burns. To open the 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.

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

Test for SCA Concentration

Heavy-Duty Coolant/Antifreeze and SCA

NOTICE

Do not exceed the recommended six percent supple­mental coolant additive concentration.

When any servicing or repair of the engine cooling

NOTICE

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.

3. Add the correct amount of SCA. Refer to the
Operation and Maintenance Manual, “Refill
Capacities and Recommendations” for more
information on SCA requirements.

M0068760 85

Maintenance Section

Diesel Exhaust Fluid - Fill

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.

i06615853

Diesel Exhaust Fluid - Fill

1. Before filling the DEF tank, ensure that the DEF

lines have been purged. Purging of the DEF lines
will take place, after the engine has stopped. Only
after purging the DEF lines should the DEF tank
be filled. For more information on the time taken
for purging the DEF lines, refer to this Operation
and Maintenance Manual, “Battery Disconnect
Switch”.

2. Ensure the DEF cap (1) and the surrounding area
is clean and free from dirt. Ensure that all
equipment use in filling the tank is clean and free
from dirt.

3. Remove the DEF cap from the tank.

4. Fill the tank with the required amount of DEF.

Ensure that dirt is not introduced into the tank
during filling. Do not over fill the tank. The DEF will
require room for expansion.

Note: Always fill the DEF tank on level ground. Cold
weather can affect DEF, refer to this Operation, and
Maintenance Manual, “Diesel Exhaust Fluid in cold
Weather” for more information.

5. The opening on the DEF tank (2) is a special
diameter. Ensure that the correct nozzle is used
when filling the DEF tank.

Illustration 69 g03714036

Typical example

Ensure that the correct specification Diesel Exhaust
Fluid (DEF) is used. Ensure the cleanliness of the
DEF, refer to this Operation and Maintenance
Manual, “Fluid Recommendations” for more

information.

Care should be taken when dispensing DEF. Spills
should be cleaned immediately. All surfaces should
be wiped clean and rinsed with water.

DEF that has been split will crystallize when the
water within the liquid evaporates. Split DEF will
attack paint and metal. If DEF is split, wash the area
with water.

Caution should be used when dispensing DEF near
an engine that has recently been running. Spilling
DEF onto hot components may cause the release of
ammonia vapors. Do not breathe ammonia vapors.
Do not clean up any spills with bleach.

Note: At key on the DEF level gauge will show the
last known DEF level and will transition to the new
DEF level value.

6. Install the DEF cap. Check visually the DEF tank
for leakage.

i06094911

Diesel Exhaust Fluid Filter ­Replace

• Diesel Exhaust Fluid (DEF)

Ensure that the DEF tank is full before starting work.

86 M0068760
Maintenance Section

Diesel Particulate Filter - Clean

Illustration 70 g03332612

Typical Example

Personal injury can result from improper han­dling of chemicals.

Make sure you use all the necessary protective
equipment required to do the job.

Make sure that you read and understand all direc­tions and hazards described on the labels and

material safety data sheet of any chemical that is
used.

Observe all safety precautions recommended by
the chemical manufacturer for handling, storage,
and disposal of chemicals.

NOTICE

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

1. Remove the DEF filter cap (3) with a 27mm Bi-Hex
socket.

2. Remove the rubber cone insert (2) from the DEF
filter (1).

Illustration 71 g03332637

Typical Example

3. Insert the DEF filter removal tool (4) into the DEF
filter (1) and remove the DEF filter (1).

Note: Avoid twisting the DEF filter (1) upon removal.
Twisting may cause a tear.

4. Clean the area around the filter housing.

5. Lubricate the seals of the new DEF filter (1) with

diesel exhaust fluid or distilled water.

6. Install new DEF filter (1) and rubber cone insert.

Note: Avoid twisting the DEF filter (1) upon

installation. Twisting may cause a tear.

7. Install the cap (3). Torque the cap to 20 N·m
(177 lb in).

i06094913

Diesel Particulate Filter - Clean

Consult your Perkins distributor when the diesel
particulate filter needs to be cleaned for the options
that are available.

The ash monitoring system within the electric control
module will require a reset.

M0068760 87

Maintenance Section

Driven Equipment - Check

i02151646

Driven Equipment - Check

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

• Inspection

• Adjustment

• Lubrication

• Other maintenance recommendations

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

i06657165

Electronic Unit Injector ­Inspect/Adjust

i03991933

Engine - Clean

Personal injury or death can result from high
voltage.

Moisture can create paths of electrical
conductivity.

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

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:

The Electronic Control Module produces high
voltage. To prevent personal injury make sure the
Electronic Control Module is not powered and the
unit injector solenoids are disconnected.

NOTICE

The camshafts must be correctly timed with the
crankshaft before an adjustment of the unit injector
lash is made. The timing pins must be removed from
the camshafts before the crankshaft is turned or dam-

age to the cylinder block will be the result.

The operation of Perkins engines with improper
adjustments of the electronic unit injector can reduce
engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
component life.

Adjust the electronic unit injector at the same interval
as the valve lash adjustment.

Refer to Systems Operation Testing and Adjusting,
Electronic Unit Injector - Adjust for more information,
or contact your Perkins distributor.

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

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

88 M0068760
Maintenance Section

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

Aftertreatment

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

i06606856

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

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.

NOTICE

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

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 Cleaner

The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner
element.

When the engine is operating in environments that
are dusty or dirty, air cleaner elements may require
more frequent replacement.

If equipped, perform maintenance on the pre-cleaner
or the dust bowl before performing maintenance on
the air filter elements.

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 pre-cleaner (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.

Illustration 72 g06043462

Typical example

Note: Do not allow dirt to enter the air system during
replacement of the air filter elements.

1. Clean the outer casing of the air cleaner before
removing the end cover (3).

2. Release the clips (4) and remove the end cover (3)
from air cleaner body (1).

3. Remove the primary air filter element (2) and
remove the secondary air filter element (not
shown) from air cleaner body (1). Ensure that the
inner body of the air cleaner is clean and free from
dirt. Ensure that the inner of the air cleaner cover ,
(3) is clean and free from dirt.

M0068760 89

Maintenance Section

Engine Air Cleaner Service Indicator - Inspect

4. Install a new secondary air filter element (not
shown). Install a new primary air filter element (2)
and install end cover (3). Ensure the clips (4) are
located securely.

i06103548

Engine Air Cleaner Service
Indicator - Inspect

(If Equipped)

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.

• 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.

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

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 73 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.

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.

i06606939

Engine Oil Level - Check

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

• Check for ease of resetting. The service indicator
should reset in less than three pushes.

90 M0068760
Maintenance Section

Engine Oil Sample - Obtain

Illustration 74 g06043530

Typical example

(1) Oil level gauge (Dipstick)
(2) Oil filler cap

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 level gauge to check engine 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).

2. If engine oil is required, remove oil filler cap to add
engine oil.

3. To choose the correct type of oil for this engine,
refer to this Operation and Maintenance Manual,
“Fluid Recommendations”.

Illustration 75 g00110310

Partial view of the oil level gauge

(Y) “ADD” mark
(X) “FULL” mark

NOTICE

Perform this maintenance with the engine stopped.

4. Clean the oil filler cap and install the oil filler cap.

5. 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

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.

M0068760 91

Maintenance Section

Engine Oil and Filter - Change

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

Obtain the Sample and the
Analysis

Hot oil and hot components 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.

i06606986

Engine Oil and Filter - Change

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

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.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened
component life.

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.

Drain the Engine Lubricating Oil

Note: Ensure that the vessel that will be used is large

enough to collect the waste oil.

After the engine has been run at the normal
operating temperature, stop the engine. Use one of
the following methods to drain the engine oil pan:

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

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

92 M0068760
Maintenance Section

Engine Valve Lash - Check

• If the engine is not equipped with a drain valve,
remove the oil drain plug in order 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

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. Remove the oil filter with a suitable tool.

4. Install the new oil filter (3). Spin on the oil filter until

the O ring 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.

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

3. Stop the engine and allow the oil to drain back to
the oil pan for a minimum of 10 minutes.

Illustration 76 g06043562

Typical example

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. .Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the ADD
and FULL marks on the side of the oil level gauge.

i05969949

Engine Valve Lash - Check

The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. 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 by Perkins as
part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.

NOTICE

Only qualified service personel should perform this
maintenance. Refer to the Service Manual or your au­thorized Perkins dealer or your Perkins distributor for
the complete valve lash adjustment procedure.

Operation of Perkins engines with incorrect valve
lash can reduce engine efficiency, and also reduce
engine component life.

M0068760 93

Maintenance Section

Fuel System - Prime

1. The fuel system can be primed from the keyswitch
or from a remote mounted switch (2).

Ensure that the engine can not be started while
this maintenance is being performed. To help pre­vent possible injury, do not use the starting motor
to turn the flywheel.

Hot engine components can cause burns. Allow
additional time for the engine to cool before
measuring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuring
the valve lash. 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.

i06614084

2. Turn the fuel priming switch (2) to the ON position.
Hold the fuel priming switch in the ON position for
2 minutes.

3. Verify that the water separator is full of fuel.

4. If the water separator is not full of fuel, turn the fuel

priming switch OFF and then turn the engine start
switch ON. This action will cycle the fuel priming
pump again.

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 1.

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.

Fuel System - Prime

i06614133

Do not allow dirt to enter the fuel system. Thoroughly

NOTICE

clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-

nected fuel system component.

Fuel System Primary Filter
(Water Separator) Element ­Replace

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 discon-

nected fuel system component.

NOTICE

Do not fill fuel filters with fuel before installing
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.

Illustration 77 g06046130

(1) Fuel priming pump
(2) Fuel priming switch

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.

94 M0068760
Maintenance Section

Fuel System Primary Filter/Water Separator - Drain

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).

i06616051

Fuel System Primary Filter/
Water Separator - Drain

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 discon-

nected fuel system component.

Illustration 78 g06046186

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 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.

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.

Illustration 79 g03807817

Typical example

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.

2. Close drain (3).

NOTICE

The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight­ened securely to help prevent air from entering the
fuel system.

M0068760 95

Maintenance Section

Fuel System Secondary Filter - Replace

i06605835

Fuel System Secondary Filter ­Replace

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.

Do not allow dirt to enter the fuel system. Thoroughly

NOTICE

clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected fuel system components.

NOTICE

Ensure that the engine is stopped before any servic­ing 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.

Illustration 80 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.

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”.

96 M0068760
Maintenance Section

Fuel Tank Water and Sediment - Drain

i02348492

Fuel Tank Water and Sediment

- Drain

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.

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.

i03965989

Grounding Stud - Inspect/
Clean/Tighten

Drain the Water and the Sediment

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

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

drain valve.

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

Fill the fuel tank after operating the engine in order to
drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.

Illustration 81 g01376112

The grounding stud is located on the upper left corner
of the engine control module.

Inspect the OEM harness for good connections.
Inspect the condition of the OEM harness.

M0068760 97

Maintenance Section

Hoses and Clamps - Inspect/Replace

The grounding stud must have a wire ground to the
battery. Tighten the grounding stud 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 grounding stud 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.

• Keep the grounding stud and the strap clean and

coated with MPGM grease or petroleum jelly.

i06103230

Hoses and Clamps - Inspect/
Replace

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.

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

• 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.

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

Inspect all hoses for leaks that are caused by the
following conditions:

• Cracking

• Softness

• Loose clamps

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

• Armoring that is embedded in the outer covering

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”.

98 M0068760
Maintenance Section

Overhaul Considerations

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

Overhaul Considerations

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.

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.

For an overhaul solution, contact your Perkins
distributor.

i04020194

Radiator - Clean

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.

i02568202

Starting Motor - Inspect

Perkins recommends a scheduled inspection of the
starting motor. If the starting motor fails, the engine
may not start in an emergency situation.

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.

i06101140

Walk-Around Inspection

Inspect the Engine for Leaks and
for Loose Connections

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

M0068760 99

Maintenance Section

DEF Filler Screen - Clean

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 proper place. Repair

damaged guards or replace missing guards.

• Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system
contamination.

NOTICE

For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and
correct the leak. If leaking is suspected, check the flu­id levels more often than recommended until the leak

is found or fixed, or until the suspicion of a leak is
proved to be unwarranted.

NOTICE

Accumulated grease and/or oil on an engine or deck
is a fire hazard. Remove this debris with steam clean-

ing or high pressure water.

• Ensure that the cooling lines are properly 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. It is normal for a small amount of
leakage to occur as the engine cools down and the
parts contract.

Excessive coolant leakage may indicate the need to
replace the water pump 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.

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.

• 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.

Aftertreatment System

Check the condition of the coolant lines, Diesel
Exhaust Fluid (DEF) lines, and electrical

connections. Check that all clamps, clips, and tie­wraps are secure and in good condition. Check that
the DEF filler cap is secure and that the cap is clean
and free from dirt.

Check the level of DEF in the tank is adequate for
operational purpose, if necessary fill the DEF tank.

i05921440

DEF Filler Screen - Clean

NOTICE

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

• 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.

100 M0068760
Maintenance Section

Injector (Diesel Exhaust Fluid) - Replace

i06605857

Injector (Diesel Exhaust Fluid)

- Replace

Illustration 82 g03725939

Typical example

1. Ensure that the area around cap on the Diesel

Exhaust Fluid (DEF) tank is clean. Remove cap
(1).

2. Using a suitable tool, press the tabs (2) in order to

release the tabs. With the tabs released remove
the filter screen (3) from DEF tank neck adapter
(4).

3. The filter screen can be cleaned in clean water and

dried using compressed air. Refer to this
Operation and Maintenance Manual, “General
Hazard Information” for information on using
compressed air.

4. If the filter screen cannot be cleaned or the filter

screen is damaged, then the filter screen must be
replaced.

5. Install filter screen (3) into DEF tank neck adapter

(4). Press filter screen into neck adapter and
ensure that tabs (2) are located correctly. Install
cap (1).

Illustration 83 g06043006

Typical example

1. The Diesel Exhaust Fluid (DEF) injector (2) must
be removed from the body of the aftertreatment
regeneration device (1) and a new DEF injector
installed. The DEF lines, coolant lines, and the
electrical connection will need to be removed to
replace the DEF injector. For more information
refer to Disassembly and Assembly, DEF Injector
and Mounting Remove and Install.

i06605733

DEF Manifold Filters - Replace

NOTICE

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