Perkins Engine 4012-46A Service Manual

Download

Page 1

Operation and Maintenance Manual

SEBU8191-01

November 2011

4012-46A Industrial Engine

(Engine)

S12

Page 2

Important Safety Information

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

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

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

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

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

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

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

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

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

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

replacement parts.

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

death.

Page 3

SEBU8191-01 3

Table of Contents

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

Safety Section

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

General Hazard Information ................................... 5

Burn Prevention ...................................................... 7

Fire Prevention and Explosion Prevention .............. 7

Crushing Prevention and Cutting Prevention .......... 9

Mounting and Dismounting ..................................... 9

Before Starting Engine .......................................... 10

Engine Starting ..................................................... 10

Engine Stopping ................................................... 10

Electrical System ................................................... 11

Index Section

Index ............................... ...................................... 74

Engine Electronics ................................................. 11

Product Information Section

General Information .............................................. 12

Model Views ......................................................... 13

Product Identiﬁcation Information ........................ 17

Operation Section

Lifting and Storage ................................................ 19

Features and Controls .......................................... 20

Engine Starting ..................................................... 23

Engine Operation .................................................. 25

Engine Stopping ................................................... 26

Maintenance Section

Reﬁll Capacities .................................................... 27

Maintenance Interval Schedule ............................ 40

Warranty Section

Warranty Information ............................................ 73

Page 4

4 SEBU8191-01 Foreword

Foreword

Literature Information

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

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

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

Safety

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

g situations. Read and understand the basic

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

on this product.

repair

ntains safety, operation instructions,

re holder or literature storage area. Read,

ency.

ls or attachments that may be different

nt and advancement of product design

garding your engine, or this manual, please

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

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

ive maintenance program is followed, a

imize operating costs through cost

rvice should be performed at the

lso governs the Maintenance Interval

t lubrication and maintenance than is

Maintenance Intervals

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

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

nce schedules be reproduced and displayed

f the engine's permanent record.

utor can assist you in adjusting your

Overhaul

Opera

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

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

tion

. They assist with developing the skills and

lop as the operator gains knowledge of the

peration section is a reference for operators.

stopping the engine. This section also includes a

Maintenance

e maintenance section is a guide to engine care.

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

tervals. Items in the maintenance schedule are

in referenced to detailed instructions that follow.

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

e interval and the maintenance items in that

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

r Perkins distributor offers a variety of options

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

r failure overhaul options available. Consult with

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

California Proposition 65 Warning

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

th defects, and other reproductive harm. Battery

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

Page 5

SEBU8191-01 5

Safety Section

Safety Messages

Safety Section

i03835895

Safety Message s

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

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

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

lacement part. Your Perkins dealer or your

several speciﬁc warning signs on your

iliar with all warning signs.

g signs or replace the warning signs if

ng signs. Do not use solvents, gasoline, or

signs. The warning signs that are loosened

any warning sign that is damaged or

(2) Hot Coolant

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

(1) Universal Warning

Do not operate or work on this equipment unless

ave read and understand the instructions

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

the warnings could result in serious injury

heed or death.

Illustration 1

g01231164

Illustration 2

g01231165

i02328435

General Hazard Information

Illustration 3

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment.

g00104545

Page 6

6 SEBU8191-01 Safety Section General Hazard Information

Illustration 4

Wear a hard hat, protective glasses, and other protective equipment, as required.

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

Make sure that all protective guards and all covers are secured in place on the engine.

Keep the engine free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps.

g00702020

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

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

ed air and/or water is used for

efaceshield.

205 kPa (30 psi). The maximum

Fluid Penetration

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

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

ulic ﬂuid or items such as pipe plugs to

ve any hydraulic components or parts

ts or parts until pressure has been relieved

he hydraulic pressure.

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

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Report all necessary repairs.

Do not allow unauthorized personnel on the equipment.

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

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

Pressure Air and Water

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

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

Illustration 5

Always use a board or cardboard when you check for a leak. Leaking ﬂuid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If ﬂuid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

g00687600

Containing Fluid Spillage

Care must be taken in order to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Make provision to collect the ﬂuid with a suitable container before any compartment is opened or before any component is disassembled.

Only use the tools that are suitable for collecting

•

ﬂuids and equipment that is suitable for collecting ﬂuids.

Page 7

SEBU8191-01 7

Safety Section

Burn Prevention

Only use the too

•

ﬂuids and equipment that is suitable for containing ﬂuids.

Obey all local regulations for the disposal of liquids.

ls that are suitable for containing

i02334785

Burn Prevention

Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine.

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

After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines.

Oils

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

Batteries

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.

i0232072

Fire Prevention an d Explosion Preventi

Allow the pressure to be purged in the air system, in the hydraulic system, in the lubrication system, or in the cooling system before any lines, ﬁttings or related items are disconnected.

Coolant

When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

Check the coolant level after the engine has stopped and the engine has been allowed to cool.

Ensure that the ﬁller cap is cool before removing the ﬁller cap. The ﬁller cap must be cool enough to touch withabarehand.Removetheﬁller cap slowly in order to relieve pressure.

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

stration 6

Illu

All fuels, most lubricants, and some coolant mixtures

ammable.

are ﬂ

Flammable ﬂuids that are leaking or spilled onto hot

faces or onto electrical components can cause

sur 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

e removed.

Determinewhethertheenginewillbeoperatedinan

vironment that allows combustible gases to be

en drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury,

roperty damage, or engine damage could result.

If the application involves the presence of combustible

ases, consult your Perkins dealer and/or your

g Perkins distributor for additional information about suitable protection devices.

g00704000

Page 8

8 SEBU8191-01 Safety Section Fire Prevention and Explosion Prevention

Remove all ﬂamm

able combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any ﬂammable combustible materials or c

onductive materials to accumulate on

the engine.

Store fuels a

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

. Do not smoke in areas that are used for

storing ﬂammable materials.

Do not expos

e the engine to any ﬂame.

Exhaust shields (if equipped) protect hot exhaust component

s 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. All electrical wires must be correctly routed and securely attached. Check al

l electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all elec

trical connections.

Oil ﬁlters and f

uel ﬁlters must be correctly installed. The ﬁlter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for mor

Illustration 7

e information.

g00704059

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

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

se 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

ained battery cables will help to prevent arcing

maint or sparking.

Contact with high pressure fuel may cause ﬂuid

tration and burn hazards. High pressure fu-

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

uctions may cause personal injury or death.

str

After the engine has stopped, you must wait for 60

conds in order to allow the fuel pressure to be

se purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines.

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

ust be correctly routed. The lines and hoses must

m have adequate support and secure clamps.

Illustration 8

g00704135

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

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

Page 9

SEBU8191-01 9

Safety Section

Crushing Prevention and Cutting Prevention

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

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

The batteries must be kept clean. The covers (if equippe recommended cables, connections, and battery box covers when the engine is operated.

er cable connections can cause

d) must be kept on the cells. Use the

Fire Extinguisher

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

e ﬁre extinguisher and service the ﬁre

Lines, Tubes and Hoses

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

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

Replace the parts if any of the following conditions are pre

erkins distributor for replacement parts.

sent:

i02143194

Crushing Prevention and Cutting Preve

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

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

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

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

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

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

ve the guards in place until maintenance

be injured by ﬂying debris.

ntion

i02235492

Mounting and Dismounting

High pressure fuel line or lines are removed.

•

End ﬁttings are damaged or leaking.

•

coverings are chafed or cut.

Outer

•

Wires are exposed.

•

Outer coverings are ballooning.

•

ible part of the hoses are kinked.

Flex

•

Outer covers have embedded armoring.

•

End ﬁttings are displaced.

•

e sure that all clamps, guards, and heat shields

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

ts, and excessive heat.

par

Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair.

Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.

Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.

Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies.

Page 10

10 SEBU8191-01 Safety Section Before Starting Engine

i02813489

Before Starting Engine

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

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

Inspect the engine for potential hazards.

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

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

tial start-up of an engine that is new,

hed by shutting off the air and/or fuel

hutdown should occur automatically for

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

ee of personnel.

suitable for the conditions. Ensure that all

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

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

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

Note: Do not use Lube oil heaters.

Engine ex which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If t vent the engine exhaust to the outside.

guards and all protective covers must

is caused by parts in rotation, work

theengineaccordingtotheprocedure

owing the correct procedure will help to

jury.

correctly, check the water temperature

haust contains products of combustion

he engine is started in an enclosed area,

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

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

See th adjustments.

ective guards and all protective covers must

t that is caused by parts in rotation, work

ypass the automatic shutoff circuits. Do not

its are also provided in order to help prevent

e Service Manual for repairs and for

i02414669

Engine Starting

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

i02414676

Engine St opp ing

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

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

Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled. In the event of an overspeed condition, the air shutoff valves will operate. After operation, the air shutoff valves must be manually reset.

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

Page 11

SEBU8191-01 11

Safety Section

Electrical System

i02414678

Electrical System

Never disconn circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that ar

To help prevent sparks from igniting combustible gases that a negative “−” cable should be connected last from the external power source to the negative “−” terminal of the starti

Check the electrical wires daily for wires that arelooseo connections before the engine is started. Repair all frayed electrical wires before the engine is started. See the Op speciﬁc starting instructions.

Engines t ground straps can be damaged by electrical discharge.

ect any charging unit circuit or battery

e produced by some batteries to ignite.

re produced by some batteries, the

ng motor.

r frayed. Tighten all loose electrical

eration and Maintenance Manual for

hat are installed without engine-to-frame

Setpoint adjus

•

Sensors

•

Wiring Harness

•

ters (if equipped)

System Description

The system is (ECU). The ECU contains a microprocessor that has an Electronic Programmable Read Only Memory (EPROM). Th are stored in the EPROM. The actuator is connected to the fuel injectors via a mechanical linkage.

A laptop computer is used to set the operating parameters of the governor. The laptop computer is connected operating parameters for the governor should only be modiﬁed by a trained Perkins representative. Refer to the Speci for more information.

controlled by an Electronic control Unit

e operating parameters for the governor

to the governor via an interface cable. The

al Instruction, “Pandoras Digital Governor”

To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame ground s used. This path may be provided by way of a direct engine ground to the frame.

The connections for the grounds should be tight and free of corrosion. The engine alternator must be groun a wire that is adequate to handle the full charging current of the alternator.

trap with a direct path to the battery must be

ded to the negative “-” battery terminal with

i0241

4684

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.

The engine is controlled by a digital Pandoras governor. The control system includes the following components.

Control unit

•

Actuator

•

Page 12

12 SEBU8191-01 Product Information Section General Information

Product Information Section

General Infor mation

i02640420

Welding on Engines with Electronic Controls

NOTICE Proper welding procedures are necessary in order to avoid damage to the engine's ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the component. If removal of the component is not possible, the following procedure must be followed when you weld with a unit that is equipped with an Electronic Engine. The following procedure is considered to be the safest procedure to weld a component. This procedure should provide a minimum risk of damage to electronic components.

NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other components.

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

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

OFF position.

2. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is provided, open the switch.

Illustration 9

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

(1) Engine (2) Welding rod (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) Maximum distance between the c ompo nent that is being

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

4. Connect the welding ground cable directly to the

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

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

g01324562

3. Disconnect the connectors from the ECM.

5. Protect the wiring harness from welding debris

and spatter.

6. Use standard welding practices to weld the

materials.

Page 13

SEBU8191-01 13

Product Information Section

Model Views

i03754026

Model View Illustrations

4012-46A

The following model views show typical features of the engine. may appear different from the Illustrations.

Due to individual applications, engines

Note: Only the following Illustrations.

serviced components are identiﬁed on

Page 14

14 SEBU8191-01 Product Information Section Model Views

Illustration 10

Typical example

Left side view of engine

(1) Radiator cap (2) Thermostat housing (3) C oolant temperature switch (4) Air cleaner (5) Res triction indicator for air cleaner

(6) Air shutoff valve (7) Timing inspection hole (8) Inspection covers for crankcase (9) 3x Oil ﬁlters (10) Oil cooler

g02090055

(11) Oil drain plug (12) O il level gauge (13) Oil ﬁ ller (14) Crankshaft damper (15) Engine crankcase breather

Page 15

SEBU8191-01 15

Product Information Section

Model Views

Illustration 11

Typical example

Right side view of engine

(1) Air shutoff valve (2) Res triction indicator for air cleaner (3) Air cleaner (4) Electronic governor control unit (5) C oolant temperature switch (6) Thermostat housing

(7) Aftercooler (8) Radiator (9) Engine crankcase breather (10) Alternator (11) Primary fuel ﬁlter/water separator (12) Oil pump

i03754051

Engine De script ion

The 4012-46A Engine model is designed for power generation. The engine is available with turbocharged aftercooled aspiration.

g02090056

(13) Fuel priming pump (14) Oil pan drain plug (15) Oil cooler (16) 3x Oil ﬁlters (17) Starter relay (18) 2x Starting motors

Engine Speciﬁcations

te: The number 1 cylinders are to the front. The

front of the engine is farthest from the ﬂywheel. Bank A cylinders are on the right-hand side of the

ngine. Bank B cylinders are on the left-hand side of

e the engine. To determine the left and right sides of the engine, stand behind the ﬂywheel and face the

ampers.

Page 16

16 SEBU8191-01 Product Information Section Model Views

Illustration 12

4012-46A Engine model

(A) Bank (B) Bank (X) Inlet valves (Y) Exhaust valves

Table 1

4012-46A Engine Speciﬁcations

Cycle 4 Stroke

Number of Cylinders

Conﬁguration Vee-form

Bore 160 mm (6.299 inch)

Strok

Displacement

Compression Ratio

Rotation (ﬂywheel end)

Firing Order

Inlet Valve Lash (Cold)

Exhaust Valve Lash (Cold)

190 mm

45.84 L (2797.328 in

Counterclockwise

1A-6B-5A-2B-3A-4B-6A-1B-2A-

0.40 mm (0.016 inch)

(7.480 inch)

13:1

5B-4A-3B

g01210840

)

The engine lubr

icating oil is supplied by a gear-driven pump. The lubrication oil is cooled and ﬁltered. Bypass valves provide unrestricted ﬂow of lubrication oil to the engi

nepartswhenoilviscosityishigh. Bypass valves can also provide unrestricted ﬂow of lubrication oil to the engine parts if the oil ﬁlter element shou

ld become plugged.

Engine efﬁciency, efﬁciency of emission controls, and engine perf

ormance depend on adherence to proper operation and maintenance recommendations. Engine performance and efﬁciency also depend on the use of re

commended fuels, lubrication oils, and coolants. Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for more informati

on on maintenance items.

Engine Cooling and Lubrication

The cooling system consists of the following components:

Gear-driven water pumps

•

Water temperature regulators which regulate the

•

engine coolant temperature

Gear-driven oil pump (gear type)

•

Oil coolers

•

Page 17

SEBU8191-01 17

Product Information Section

Product Identiﬁcation Information

i03754093

Plate Locations and Film Locations

Engine Identiﬁcation

Perkins engines are identiﬁed by an engine serial number.

A typical example of an engine serial number is DGB M**** U00001V.

_________________________________________ Made in Stafford

____________________________________ Application (Table 2)

________________________________ Type of engine (Table 3)

________________________ Number of cylinders (Table 4)

__________________________________Fixed build number

*****

____________________________ Built in the United Kingdom

Table 3

F TG

S TEG3

W TRW2

X TRW3

Table 4

F 6

H 8

M 12

R 16

Type of engine (Diesel)

TAG

TAG1

TAG2

TAG3

TWG

TWG2

TWG3

TRG1

TEG2

Number of Cylinders

00001

Table 2

____________________________________Engine Number

_____________________________________ Year of Manufacture

Application

G Genset

Perkins dealers and Perkins distributors require all of these numbers in order to determine the components that were included in the engine. This permits accurate identiﬁcation of replacement part numbers.

Page 18

18 SEBU8191-01 Product Information Section Product Identiﬁcation Information

Serial Number Plate

Illustration 13

Serial number plate

The engine serial number plate contains the following information:

Place of manufacture

•

Telephone number of manufacturer

•

Fax number of manufacturer

•

Type of engine

•

Engine serial number

•

Rated speed

•

Power output

•

Engine timing

•

Rating

•

g01266904

Illustration 14

The location of the serial number plate for vee-form engines

The serial number plate (1) on a vee-form engine is located on the rear face of the cylinder block (bank A). See Illustration 14.

g01229580

Page 19

SEBU8191-01 19

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i02414727

Engine Lifting

NOTICE 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.

To re m ov e t he e n that are on the engine. If necessary, remove engine components in order to avoid damage from the lifting device.

Lifting eyes are designed and installed for speciﬁc engine arran and/or the engine make the lifting eyes and the lifting ﬁxtures obsolete. If alterations are made, ensure that correc your Perkins dealer or your Perkins distributor for information regarding ﬁxtures for correct engine lifting.

t lifting devices are provided. Consult

gine ONLY, use the lifting eyes

gements. Alterations to the lifting eyes

i03781209

Engine Storage

Refer to Perkins Engine Company Limited, Stafford, ST16 3UB for information on engine storage.

There are three different levels of engine storage. Level “A, B and C”.

lustration 15

Level “A ”

Level “A” will give protection for 12 months for diesel engines and for gas engines. This level is used for engines that are transported in a container or by a truck.

Level “B ”

This level is additional to level “A”. Level “B ” will give protection under normal conditions of storage from −15° to +55°C (5° to 99°F) and “90%” relative humidity, for a maximum of 2 year.

Level “C ”

This level is additional to level “B”. Level “C” will give protection for ﬁve years in tropical or in arctic climates. Level “C” also meets MOD NES 724 Level “J” for Europe, when engines are stored in an unheated building or in the open under a waterproof cover.

g01230422

Use a hoist to remove heavy components. Use a

ifting beam (A) to lift the engine. All supporting

l members (chains and cables) should be parallel to each other. The chains and cables should be

erpendicular to the top of the object that is being

p lifted.

Page 20

20 SEBU8191-01 Operation Section Features and Controls

Features and Controls

i02415217

Monitoring System

The engine is equipped with sensors or switches to monitor the following parameters:

Coolant temperature (Switch)

•

Oil pressure (Switch)

•

Intake manifold boost pressure (Sensor)

•

Exhaust temperature (if equipped)

•

Engine speed (Sensor)

•

Engine overspeed (Sensor or Switch)

•

Sensors and Electrical Components

i02415219

Illustration 16

Right side view of engine

(1) Electronic control unit (ECU) (2) C oolant temperature switch (3) B oost pressure sensor (4) Speed sensor (5) Oil pressure switch

g01231519

Sensor Locations

trations 16 and 17 show the typical locations

Illus of the sensors on the engine. Speciﬁc engines may appear different from the illustrations due to

erences in applications. Illustration 16 shows the

diff location of the Electronic Control Unit (ECU).

Illustration 17

Left side view of engine

) Coolant temperature switch

) Boost pressure sensor

) Oil pressure switch

) Overspeed sensor

g01

231520

Page 21

SEBU8191-01 21

Operation Section

Features and Controls

Coolant Temperature Switches

Illustration 18

Coolant temperature switch

The coolant temperature switches (2) monitor the engine coolant temperature. The switches are supplied for connecting to an OEM supplied panel.

g01231514

Boost Pressure Sensors

Speed Sensor

Illustration 20

Speed sensor

The speed sensor (4) should be serviced at the required maintenance interval. Refer to the Operation and Maintenance Manual, “Speed Sensor, Clean/Inspect”.

Failure of the Speed Sensor

g01231517

Illustration 19

Boost pressure sensor

g01231515

The boost pressure sensor (3) measures the pressure in the inlet air manifold. A signal is sent to the ECU (1).

If the ECU (1) does not receive a signal from the speed sensor (4), the engine cannot run.

If the ECU does not receive a signal from the speed sensor (4), the engine will shut down. A faulty speed sensor should be replaced.

Note: Intermittent failure of the speed sensor will cause the engine to run erratically. This may also cause overspeed.

Page 22

22 SEBU8191-01 Operation Section Features and Controls

Engine Oil Pressure Switch

Illustration 21

Engine oil pressure switch

g01278615

The engine oil pressure switch (5) is mounted in the main oil gallery. The engine oil pressure switches are supplied for connecting to an OEM supplied panel (1).

Overspeed Sensor

Illustration 22

Overspeed sensor

g01231518

The signal from the overspeed sensor (6) is connected to the overspeed switch or the overspeed circuit in the OEM supplied panel.

Page 23

SEBU8191-01 23

Operation Section

Engine Starting

i02415220

Before Starting Engine

Before the e daily maintenance and any other periodic maintenance that is due. Refer to the Operation and Mainte Schedule” for more information.

Note: Do no controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the c

1. Open the fuel supply valve (if equipped).

2. If the engine has not been started for several

weeks, fuel may have drained from the fuel system. some air pockets will be trapped in the engine. In these instances, prime the fuel system. Refer to the O System-Prime”formoreinformation.

ngine is started, perform the required

nance Manual, “Maintenance Interval

t start the engine or move any of the

ontrols.

Also, when fuel ﬁlters have been changed,

peration and Maintenance Manual, “Fuel

b. Turn the keyswi

Hold the keyswitch in this position until the oil pressure gauge indicates 100 kPa (14.5040 psi) in the START position for an additional 10 seconds.

Note: The keyswitch is part of the OEM supplied panel. The exact procedure for starting may vary. Refer to OEM starting procedure.

c. Turn the key

d. Reconnect the speed pickup connector.

The engine is now ready to run.

supplied instructions for the correct

tch to the START position.

. Continue to hold the keyswitch

switch to the STOP position.

i02415221

Starting the Eng ine

Normal Engine Starting Procedure

Note: When possible, ensure that the engine is not

started under load.

Illustration 23

3. Ensure that the two air shutoff valves (1) are in

the OPEN position.

4. If the engine has not been started for more than

three months, the engine oil system must be primed. Follow Steps 4.a through 4.d in order to prime the engine oil system.

a. Ensure that the governor stays in the STOP

position by disconnecting the speed pickup connector on the governor control.

g01230837

1. Turn the keyswitch to the START position. The engine should start immediately.

2. Allow the keyswitch to return to the RUN position after the engine starts.

If the engine does not start after 10 seconds, return the keyswitch in the RUN position for 10 seconds. Then repeat Steps 1 and 2.

Note: If the engine fails to start after three attempts, investigate the cause.

3. After the engine has started follow Steps 3.a through 3.d.

a. Check the oil pressure.

b. Inspect the engine for leaks.

c. Ensure that the batteries for the engine are

receiving a charge.

d. After the engine has run for ﬁve minutes, check

the engine monitoring systems. Ensure that the engine is operating correctly before the load is applied.

Page 24

24 SEBU8191-01 Operation Section Engine Starting

i02415223

Cold Weather Starting

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

Startability will be improved at temperatures below +10 °C (+50 °F) from the use of a jacket water heater or extra battery capacity.

Page 25

SEBU8191-01 25

Operation Section

Engine Operation

i02415225

Engine Operation

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

Gauge read and the data should be recorded frequently while the engine is operating. Comparing the data over time will gauge.Comparingdataovertimewillalsohelp detect abnormal operating developments. Signiﬁcant changes

ration and maintenance are key factors

ce Manual are followed, costs can be

ings (if equipped) should be observed

help to determine normal readings for each

in the readings should be investigated.

i02415226

Fuel Conservation Prac tices

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

Avoid spilling fuel. Fuel expands when the fuel is

•

warmed up. The fuel may overﬂow from the fuel tank. Insp lines, as needed.

Be aware of

•

Use only the recommended fuels.

Avoid unn

•

engine is not under load, the engine should be shut down.

Observe the air cleaner service indicator frequently.

•

The air cleaner elements should be replaced when the air c

of the engine can affect the fuel

ions. Follow the recommended procedures

ect fuel lines for leaks. Repair the fuel

the properties of the different fuels.

ecessary running at a low load. If the

leaner elements are dirty.

Maintain the electrical systems. One damaged

•

battery consume excess power and excess fuel.

Ensure

•

The drive belts should be in good condition.

Ensur

•

tight. The connections should not leak.

Ensur

•

working order.

Cold

•

from the jacket water system and the exhaust system, when possible. Keep cooling system comp components in good repair. Never operate the engine without water temperature regulators. All temperatures.

cell will overwork the alternator. This will

that the drive belts are correctly adjusted.

e that all of the connections of the hoses are

e that the driven equipment is in good

engines consume excess fuel. Utilize heat

onents clean and keep cooling system

of these items will help maintain operating

Page 26

26 SEBU8191-01 Operation Section Engine Stopping

Engine Stopping

i02415227

Stopping the Engine

Note: Indiv

control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to

1. Remove the load from the engine. Allow the engine to r cool the engine.

2. Stop the e according to the shutoff system on the engine and turn the ignition key switch to the OFF position. If neces provided by the OEM.

Emergency Stopping

Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or contr

idual applications will have different

stop the engine.

un off load for ﬁve minutes in order to

ngine after the cool down period

sary, refer to the instructions that are

NOTIC

ols for normal stopping procedure.

i02415230

i02415231

After Stopping Engine

Note: Before y

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

If the engine is equipped with a service hour meter,

•

note the reading. Perform the maintenance that is in the Ope “Maintenance Interval Schedule”.

Check the c

•

between the “MIN” mark and the “MAX” mark on the engine oil level gauge.

If necessary, perform minor adjustments. Repair

•

any leaks from the low pressure fuel system and from the c

Fill the fuel tank in order to help prevent

•

accumula the fuel tank.

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

ou check the engine oil, do not operate

ration and Maintenance Manual,

rankcase oil level. Maintain the oil level

ooling, lubrication or air systems.

tion of moisture in the fuel. Do not overﬁll

NOTICE

lant Speciﬁcations that are in the Operation

The engine should be equipped with an emergency

button. For more information about the

stop emergency stop button, refer to the OEM information.

ure that any components for the external system

Ens that support the engine operation are secured after the engine is stopped.

In the event of an overspeed condition, the air shutoff valves will operate. After operation, the air shutoff

lves must be manually reset.

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

Allow the engine to cool. Check the coolant level.

•

Check the coolant for correct antifreeze protection

•

and the correct corrosion protection. Add the correct coolant/water mixture, if necessary.

Perform all required periodic maintenance on all

•

driven equipment. This maintenance is outlined in the instructions from the OEM.

Page 27

SEBU8191-01 27

Maintenance Section

Reﬁll Capacities

Maintenance Section

Reﬁll Capacities

i03754130

Reﬁll Capaci ties

Lubrication System

The reﬁll capacities for the engine crankcase reﬂect the approximate capacity of the crankcase or sump plus standard oil ﬁ lters. Auxiliary oil ﬁlter systems will require additional oil. Refer to the OEM speciﬁcations for the capacity of the auxiliary oil ﬁlter. Refer to the Operation and Maintenance Manual, “Maintenance Section” for more information on Lubricant Speciﬁcations.

Table 5

Engine

Reﬁll Capacities

Compartment or System

Crankcase Oil Sump

(1)

These values are the total capacities for the crankcase oil sump which includes the standard factory installed oil ﬁlters and oil c oolers. Engines with auxiliary oil ﬁlters will require additional oil. Refer to the OEM speciﬁcations for the capacity of the auxiliary oil ﬁlter.

(1)

Cooling System

Refer to the OEM speciﬁcations for the External System capacity. This capacity information will be

ed in order to determine the amount of coolant

need and antifreeze that is required for the Total Cooling System.

4012-46A

178 L (39.2 Imp gal)

Table 7

Engine

Reﬁll Capacities

Compartment or System 4012-46A

Minimum Capacity of Fuel Tan k

14000 L (3000 Imp gal)

i04328169

Fluid Recommendations

General Lubricant Inform a tion

The following lubricant recommendations must be followed.

Engine Manufacturers Association (EMA) Oils

The “Engine Manufacturers Association Recommended Guideline on Diesel Engine Oil” is recognized by Perkins. For detailed information about this guideline, see the latest edition of EMA publication, “EMA DHD -1”.

API Oils

The Engine Oil Licensing and Certiﬁcation System by the American Petroleum Institute (API) 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.

le 6

Tab

ine

Eng

Reﬁll Capacities

Compartment or System Liters

External System Per OEM

(1)

The External System includes a radiator w ith the following components: heat exchanger and piping. Refer to the OEM speciﬁcations. Enter the value for the capacity of the External System in this column.

(1)

Fuel System

Refer to the OEM speciﬁcations for additional information on the capacity of the Fuel System.

0546535

Illustration 24

Typical API symbol

iesel engine oils CC, CD, CD-2, and CE have

not been API authorized classiﬁcations since 1 January 1996. Table 8 summarizes the status of the

lassiﬁcations.

Page 28

28 SEBU8191-01 Maintenance Section Reﬁll Capacities

Table 8

API Classiﬁcations

Current Obsolete

CH-4, , CI-4 CE, CC, CD

CD-2

(1)

The oil CD-2 sell engine

is for a two-cycle diesel engine. Perkins does not

s that u tilize CD-2 oil.

Termin olog y

Certain abbreviations follow the nomenclature of “SAE J754”. Some classiﬁcations follow “SAE J183” abbreviat

ions, and some classiﬁcations follow the “EMA Recommended Guideline on Diesel Engine Oil”. In addition to Perkins deﬁnitions, there are other deﬁnitio

ns that will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in this publication, “Fluid Recommendations/Engine Oil” topi

Engine O

c (Maintenance Section).

Commercial Oils

The performance of commercial diesel engine oils is based on American Petroleum Institute (API) c developed in order to provide commercial lubricants for a broad range of diesel engines that operate at variou

Only use commercial oils that meet the following class

•

lassiﬁcations. These API classiﬁcations are

s conditions.

iﬁcations:

API CG-4

API CH-4

I-4

API C

DHD-1 oils will

meet the needs of high performance Perkins diesel engines that are operating in many applications. The tests and the test limits that are used to deﬁne D

HD-1 are similar to the new API CH-4 classiﬁcation. Therefore, these oils will also meet the requirements for diesel engines that require low emission

s. DHD-1 oi ls are designed to control the harmful effects of soot with improved wear resistance and improved resistance to plugging of the oil ﬁlter. These oils w

ill also provide superior piston deposit control for engines with either two-piece steel pistons or aluminum pistons.

All DHD-1 oils must complete a full test program with the base stock and with the viscosity grade of the ﬁnishe

dcommercialoil.Theuseof“APIBase Oil Interchange Guidelines” are not appropriate for DHD-1 oils. This feature reduces the variation in performan

ce that can occur when base stocks are changed in commercial oil formulations.

DHD-1 oil

s are recommended for use in extended oil change interval programs that optimize the life of the oil. These oil change interval programs are based on oil ana

lysis. DHD-1 oils are recommended for conditions that demand a premium oil. Your Perkins dealer or your Perkins distributor has the speciﬁc

nes for optimizing oil change intervals.

guideli

API CH-4 – API CH-4 oils were developed in order to meet the

requirements of the new high performance diesel engines. Also, the oil was designed to meet the requirements of the low emissions diesel engine

s. API CH-4 oils are also acceptable for use in older diesel engines and in diesel engines that use high sulfur diesel fuel. API CH-4 oils may be

n Perkins engines that use API CG-4 and API

used i CF-4 oils. API CH-4 oils will generally exceed the performance of API CG-4 oils in the following criteria:

its on pistons, control of oil consumption, wear

depos of piston rings, valve train wear, viscosity control, and corrosion.

In order to make the correct choice of a commercial

, refer to the following explanations:

oil

EMA DHD-1 – The Engine Manufacturers

ociation (EMA) has developed lubricant

Ass recommendations as an alternative to the API oil classiﬁcation system. DHD-1 is a Recommended

ideline that deﬁnes a level of oil performance for

Gu these types of diesel engines: high speed, four stroke cycle, heavy-duty, and light duty. DHD-1 oils may

used in Perkins engines when the following oils

be are recommended: API CH-4, API CG-4, and API CF-4. DHD-1 oils are intended to provide superior

rformance in comparison to API CG-4 and API

pe CF-4.

Three new engine tests were developed for the API CH-4 oil. The ﬁrst test speciﬁcally evaluates deposits

stons for engines with the two-piece steel piston.

on pi This test (piston deposit) also measures the control of oil consumption. A second test is conducted

h moderate oil soot. The second test measures

wit the following criteria: wear of piston rings, wear of cylinder liners, and resistance to corrosion. A third

test measures the following characteristics with

new high levels of soot in the oil: wear of the valve train, resistance of the oil in plugging the oil ﬁlter, and

ntrol of sludge.

Page 29

SEBU8191-01 29

Maintenance Section

Reﬁll Capacities

In addition to t

he new tests, API CH-4 oils have tougher limits for viscosity control in applications that generate high soot. The oils also have improved oxidation res

istance. API CH-4 oils must pass an additional test (piston deposit) for engines that use aluminum pistons (single piece). Oil performance is also establi

shed for engines that operate in areas

with high sulfur diesel fuel.

All of these

improvements allow the API CH-4 oil to achieve optimum oil change intervals. API CH-4 oils are recommended for use in extended oil change inte

rvals. API CH-4 oils are recommended for conditions that demand a premium oil. Your Perkins dealer or your Perkins distributor has speciﬁc guideline

s for optimizing oil change intervals.

Some commercial oils that meet the API classiﬁca

tions may require reduced oil change intervals. To determine the oil change interval, closely monitor the condition of the oil and perform a wear metal ana

lysis.

NOTICE Failure to follow these oil recommendations can cause shorten

ed engine service life due to deposits and/or

excessive wear.

Tot al Base Number (TB N) and Fuel Sulfur Levels

for Direct Injection (DI) Diesel

Engines

The To the fuel sulfur level. For direct injection engines that use distillate fuel, the minimum TBN of the new oil must b deﬁned by “ASTM D2896”. The minimum TBN of the oil is 5 regardless of fuel sulfur level. Illustration 25 demo

tal Base Number (TBN) for an oil depends on

e ten times the fuel sulfur level. The TBN is

nstrates the TBN.

Use the followi

ng guidelines for fuel sulfur levels that

exceed 1.5 percent:

Choose an oil w

•

ith the highest TBN that meets one

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

Reduce the oi

•

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

nalysis.

Excessive piston deposits can be produced by an oil withahighT

BN. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore.

NOTICE Operating Direct Injection (DI) diesel engines with fuel sulphur levels over 0.5 percent will require shortened oil chang

e intervals in order to help maintain adequate

wear protection.

Table 9

Percentage of Sulfur in the fuel

Lower than 0.5 Normal

0.5to1.0

Greater than 1.0 0.50 of normal

Oil change interval

0.75 of

normal

Lubricant Viscosity Recommendations for Direct Injection (DI) Diesel Engines

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

Refer to Table 10 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.

Illustration 25

(Y) TBN by “AST M D2896” (X) Percentage of fuel sulfur by weight (1) TBN of new oil (2) Change the oil when the TBN deteriorates to 50 percent of

the original TBN.

g00799818

Refer to Table 10 (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.

Page 30

30 SEBU8191-01 Maintenance Section Reﬁll Capacities

Table 10

Engine Oil Viscosity

EMA LRG-1

API CH-4

Viscosity Grade

SAE 10W30

SAE 15W40

Ambient Starting

Temperature

Temperatures below

−15 °C (5 °F)

−15 °C (5 °F) to

0°C(32.°F)

0°C(32.°F)to

32 °C (89.5

Temperatures above

32 °C (89.5 °F)

°F)

Synthetic Base Stock Oils

Syntheti these engines if these oils meet the performance requirements that are speciﬁed for the engine.

Synthetic base oils generally perform better than conventional oils in the following two areas:

•

Some synthetic base oils have performance characteristics that enhance the service life of the oil. P extending of the oil change intervals for any type of oil.

c base o ils are acceptable for use in

Synthetic base oils have improved ﬂow at low temperatures especially in arctic conditions.

Synthetic base oils have improved oxidation stability especially at high operating temperatures.

erkins does not recommend the automatic

Lubricants for

Cold Weather

When an engine is started and an engine is operated in ambient tem

peratures below −20 °C (−4°F),use multigrade oils that are capable of ﬂowinginlow temperatures.

These oils have lubricant viscosity grades of SAE 10W or SAE 15W.

When an engine is started and operated in ambient temperatures below −30 °C (−22 °F), use a synthetic base stock m

ultigrade oil with an 0W viscosity grade orwitha5Wviscositygrade.Useanoilwithapour point that is lower than −50 °C (−58 °F).

The number of acceptable lubricants is limited in cold-weather conditions. Perkins recommends the follow

ing lubricants for use in cold-weather

conditions:

First Cho

ice – Use oil with an EMA DHD-1

Recommended Guideline. Use a CH-4 oil that has an API license. The oil should be either SAE 0W20, SAE 0W30,

SAE 0W40, SAE 5W30, or SAE 5W40

lubricant viscosity grade.

Second C

hoice – Use an oil that has a CH-4

additive package. Although the oil has not been tested for the requirements of the API license, the oil must be e

ither SAE 0W20, SAE 0W30, SAE 0W40,

SAE 5W30, or SAE 5W40.

NOTICE Shortened engine service life could result if second choice oils are used.

Re-reﬁned Base Stock Oils

eﬁned base stock oils are acceptable for

Re-r use in Perkins engines if these oils meet the performance requirements that are speciﬁed by

kins. Re-reﬁned base stock oils can be used

Per exclusively in ﬁnished oil or in a combination with new base stock oils. The US military speciﬁcations

the speciﬁcations of other heavy equipment

and manufacturers also allow the use of re-reﬁned base stock oils that meet the same criteria.

The process that is used to make re-reﬁned base stock oil should adequately remove all wear metals

at are in the used oil and all the additives that

th are in the used oil. The process that is used to make re-reﬁned base stock oil generally involves the

rocess of vacuum distillation and hydrotreating the

p used oil. Filtering is adequate for the production of high quality, re-reﬁned base stock oil.

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 maximum service life of the engine 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 additive package of the ﬁnished oil, which could lower the performance of the ﬁnished oil. The aftermarket additive could fail to mix with the ﬁnished oil. This could produce sludge in the crankcase. Perkins discourages the use of aftermarket additives in ﬁnished oils.

Page 31

SEBU8191-01 31

Maintenance Section

Reﬁll Capacities

To achieve the b engine, conform to the following guidelines:

Select the cor

•

the “EMA Recommended Guideline on Diesel Engine Oil” or the recommended API classiﬁcation.

See the appropriate “Lubricant Viscosities” table in

•

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

At the speciﬁed interval, service the engine. Use

•

new oil and i

Perform maintenance at the intervals that are

•

speciﬁed i Manual, “Maintenance Interval Schedule”.

Oil analys

Oil samples should be taken on a regular basis for oil analysis maintenance program.

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

. Oil analysis will complement the preventive

nalysis is a diagnostic tool that is used to

the oil analysis. The oil analysis includes

est performance from a Perkins

rect oil, or a commercial oil that meets

nstall a new oil ﬁlter.

n the Operation and Maintenance

Cetane number_

•

Viscosity___________ 1.5to5.0cStat40°C(104°F)

•

Carbon residue__________________________________ 0.20%

•

Ramsbottom on 10% reidue

Sulfur content___________ 0.05% of mass, maximum

•

Distillati

•

Lubricity_________________ _____________460 micrometers

•

maximum wea

Class A2 Fuels

Cetane number_______________________________________ 45

•

Viscosity

•

Carbon residue__________________________________ 0.20%

•

Ramsbott

Sulfur content___________ 0.05% of mass, maximum

•

Distillation___________________ 56% at 350 °C (662 °F)

•

Lubrici

•

maximum wear scar on “ISO 12156 - 1”

___________ 1.5to5.5cStat40°C(104°F)

om on 10% reidue

______________________________460 micrometers

______________________________________

___________________ 56% at 350 °C (662 °F)

r scar on “ISO 12156 - 1”

The Wea

•

metals in the engine. The amount of wear metal and type of wear metal that is in the oil is analyzed. The inc 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 lubricating properties of the oil. An infrared anal new oil to the properties of the used oil sample. This analysis allows technicians to determine the a This analysis also allows technicians to verify the performance of the oil according to the speciﬁcation dur

Fue

r Rate Analysis monitors the wear of the

rease in the rate of engine wear metal in

ysis is used to compare the properties of

mount of deterioration of the oil during use.

ing the entire oil change interval.

l Speciﬁcations

Fuel Recommendations

To get the correct power and performance from the engine, use a fuel of the correct quality. The

commended fuel speciﬁcation for Perkins engines

re is shown below:

Cetane n

This indicates the properties of ignition of the fuel. Fuel wi cause of problems during cold start. This will affect combustion.

Viscosity

This i resistance is outside the limits, the engine and the engine starting performance in particular can be affe

Sulfur

High sulfur content of the fuel is not normally found in Europe, North America or Australasia. This can cau are available, it will be necessary that high alkaline lubricating oil is used in the engine or that the lub

Distillation

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

drocarbons can affect the characteristics of

hy combustion.

umber

th a low cetane number can be the root

s the resistance to ﬂow of a ﬂuid. If this

cted.

se engine wear. When only high sulfur fuels

ricating oil change interval is reduced.

lass A1 Fuels

ubricity

Page 32

32 SEBU8191-01 Maintenance Section Reﬁll Capacities

This is the capa

bility of the fuel to prevent pump wear.

Diesel engines have the ability to burn various fuels. These fuels ar

Group 1 (preferred fuels)

•

Group 2 (permissible fuels)

•

Group 1 (pre

e divided into two general groups:

ferred fuels): Speciﬁcation

“DERV to EN590”

Note: Only use Arctic fuels when the temperature is below 0 °C (32 °F). Do not use Arctic fuels when the ambient te

mperature is above 0 °C (32 °F). To ensure that the time period between cranking the engine and ﬁrst ﬁre is kept to a minimum, only use fuel of the correct vi

scosity and at the correct temperature.

Gas oil to “BS29 Class A2”

Note: If low sulfur or low sulfur aromatic fuels are used, then fuel additives can be used to increase

lubricit

Group 2 (permissible fuels): Speciﬁcation

Deterioration

•

of emissions and misﬁre at certain

operating conditions

NOTICE

Water emulsio

n fuels: These fuels are not permitted

Refer to the following fuel speciﬁcations for North America.

The preferred fuels provide maximum engine service life and performance. The preferred fuels are distillate fuels. These fuels are commonly called diesel fuel or gas oil.

The permissible fuels are crude oils or blended fuels. Use of these fuels can result in higher maintenance costs and in reduced engine service life.

Diesel fuels that meet the speciﬁcations in Table 11 will help to provide maximum engine service life and performance. In North America, diesel fuel that is identiﬁed as No. 2-D in “ASTM D975” generally meets the speciﬁcations. Table 11 is for diesel fuels that are distilled from crude oil. Diesel fuels from other sources could exhibit detrimental properties that are not deﬁned or controlled by this speciﬁcation.

These fuel speciﬁcations are considered acceptable for issues of warranty. However, these fuels may reduce t

he life of the engine, the maximum power of

theengineandthefuelefﬁciency of the engine.

“ASTM D

975 - 91 Class 1D”

“JP7, Mil T38219”

“NATO F63”

NOTICE

These fuels should have a wear scar value of 650

ometers maximum *HFRR to ISO 12156 - 1.*

micr

Low temperature fuels

cial fuels for use in cold weather may be available

Spe for engine operation at temperatures below 0 °C (32 °F). These fuels limit the formation of wax in the

l oil at low temperatures. If wax forms in the fuel

fue oil, this could stop the ﬂow of fuel oil through the ﬁlter.

te: These fuels that lack lubricity may cause the

following problems:

Table 11

Perkins Speciﬁcations for Distillate Diesel Fuel

Speciﬁcations

tics

Aroma

Ash

Carbon Residue on 10% Bottoms

Cetane Number

Cloud Point

Requirements

35% maximum “D1319”

0.02% maximum (weight)

0.35% maximum (weight)

40 minimum (DI

ines)

eng

The cloud point must not exceed the lowest expected ambient temperature.

ASTM Test

“D482”

“D524”

“D613”

(continued)

w engine power

•

Difﬁcult starting in hot conditions or in cold

•

onditions

White smoke

•

Page 33

SEBU8191-01 33

Maintenance Section

Reﬁll Capacities

(Table 11, contd)

Copper Strip Corrosion

No. 3 maximum

“D130”

10% at 282 °C (540 °F) maximum

Distillation

“D86”

90% at 360 °C (680 °F) maximum

Flash Point legal limit

“D93”

30 minimum

API Gravity

“D287”

45 maximum

6°C(10°F)

Pour Point

minimum below ambient

“D97”

temperature

0.2% maximum “D3605”

(1)

Sulfur

“D1552”

2.0 cSt minimum Kinematic Viscosity

(2)

and 4.5 cSt maximum at

“D445”

40 °C (104 °F)

Water and Sediment

Water

Sediment

Gum and Resins

(3)

0.1% m

0.1% maximum “D1744”

0.05% maximum

(weight)

10 mg per 100 mL maximum

aximum

“D1796”

“D473”

“D381”

0.38 mm

Lubricity

(4)

(0.015 inch) maximum at

“D6079”

25 °C (77 °F)

(1)

Perkins fuel systems and engine components can operate on high sulfur fuels. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal components. Fuel sulfur levels above 0.5 percent may signiﬁcantly shorten the oil change interval. For additional information, see this publication, “Fluid Recommendations/Engine Oil” topic (M aintenance Section).

(2)

The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain a 1 .4 cSt viscos ity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to bring down the viscosity to a 2 0 cSt viscosity.

(3)

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

(4)

The lubricity of a fuel is a concern with low sulfur fuel. To determine the lubricity of the fuel, use either the “ASTM D6078 Scufﬁng Load Wear Test (SBOCLE)” or t he “ASTM D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supp lier. D o not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system.

Operating wit

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

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

Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel must NOT be used in Perkins diesel engines. Severe component wear and component failures will result if HFO type fuels are used in engines that are conﬁgured to use distillate fuel.

In extreme cold ambient conditions, you may use the distillate fuels that are speciﬁed in Table 12. However, the fuel that is selected must meet the requirements that are speciﬁed in Table 11. These fuels are intended to be used in operating temperatures that are down to −54 °C (−65 °F).

Table 12

Distillate Fuels

Speciﬁcation Grade

“MIL-T-5624R” JP-5

“ASTM D1655” Jet-A-1

“MIL-T-83133D” JP-8

(1)

The fuels that are listed in this Table may not meet the requirements that are speciﬁed in the “Perkins Speciﬁ cations for D is tillate Diesel Fuel” Table. Consult the supplier for the recommended additives in order to m aintain the correct fuel lubricity.

These fuels are lighter than the No. 2 grades of fuel. The cetane number of the fuels in Table 12 must be at least 40. If the viscosity is below 1.4 cSt at 38 °C (100 °F), use the fuel only in temperatures below 0°C(32°F).Donotuseanyfuelswithaviscosity of less than 1.2 cSt at 38 °C (100 °F). Fuel cooling may be required in order to maintain the minimum viscosity of 1.4 cSt at the fuel injection pump.

There are many other diesel fuel speciﬁcations that are published by governments and by technological societies. Usually, those speciﬁcations do not review all the requirements that are addressed in this speciﬁcation. To ensure optimum engine performance, a complete fuel analysis should be obtained before engine operation. The fuel analysis should include all of the properties that are listed in Table 11.

NOTICE

(1)

Page 34

34 SEBU8191-01 Maintenance Section Reﬁll Capacities

Recommendatio

Biodiesel can be blended with distillate diesel fuel. The blends can available biodiesel blends are B5, which is 5 percent biodiesel and 95 percent distillate diesel fuel. B20, which is 20 pe diesel fuel.

Note: The pe

The U.S. distillate diesel fuel speciﬁcation “ASTM D975-09a” i

European distillate diesel fuel speciﬁcation EN590: 2010 inclu

Speciﬁcation Requirements

The neat biodiesel must conform to the latest “EN14214 or ASTM D6751” (in the USA). The biodiese 20% by volume in acceptable mineral diesel fuel meeting latest edition of “EN590 or ASTM D975 S15” designat

In United States Biodiesel blends of B6 to B20 must meet the “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 produc

In other areas of the world, the use of biodiesel

s BQ-9000 accredited and certiﬁed, or that is

that i accredited and certiﬁed by a comparable biodiesel quality body to meet similar biodiesel quality

ards is required.

stand

Engine Service Requirements

Aggressive properties of biodiesel fuel may cause debris in the fuel tank and fuel lines to be released

ntrained in the fuel. This effectively cleans

and e the fuel system. This cleaning of the fuel system can prematurely block of the fuel ﬁlters. Perkins

ommend that after the initial usage of B20

rec 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

e regular service interval should be reduced to 250

th hours.

rcentages given are volume-based.

ncludes up to B5 (5 percent) biodiesel.

des up B7 (7 percent) biodiesel.

l can only be blended in mixture of up to

ion.

requirements listed in the latest edition of

ers and BQ-9000 certiﬁed distributors.

ns for Biodiesel

be used as fuel. The most commonly

rcent biodiesel and 80 percent distillate

Crankcase oil f

•

biodiesel or biodiesel blends are used. This increased level of fuel dilution when using biodiesel or biodiesel b lower volatility of biodiesel. In-cylinder emissions control strategies utilized in many of the industrial latest engin of biodiesel concentration in the sump. There is recent evidence that the unburnt fuel can form “treacle” l accumulate the deposits have been shown to block oil ways leading to engine failure. This reinforces the need to o

Perkins recommend the use of oil analysis in order

•

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

Performance Related Issues

Duetothe distillate fuel B20 will cause a power loss. In addition, over time the power may deteriorate further due to deposits

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

The eng

•

conditions.

The tu

•

The engine emissions can deteriorate.

•

General Requirements

Biod in long-term problems in the storage of biodiesel. Biodiesel fuel should be used within 6 months of manu 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 lim blends or, while accepting some risk, limit biodiesel blend to a maximum of B5. Examples of applications

at should limit the use of biodiesel are the following:

th Standby Generator sets and certain emergency vehicles.

in the fuel injectors.

ase in fuel system deposits, most signiﬁcant

ed fuel injection or cause other functional

rbochargers may have a reduced service life.

iesel has poor oxidation stability, which can result

facture. Equipment should not be stored with

ited operational time either not use B20 biodiesel

uel dilution can be higher when

lends is related to the typically

e designs may lead to a higher level

ike deposits in the engine oil pan. If left to

perate a reduced oil change interval.

e quality of the engine oil if biodiesel

lower energy content than the standard

ine may be difﬁcult to start in cold

Page 35

SEBU8191-01 35

Maintenance Section

Reﬁll Capacities

Perkins strong operated engines have the fuel systems, including fuel tanks, ﬂashed with conventional diesel fuel before prolon 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 ﬁ assistance in selecting appropriate anti-microbial additive.

Water accelerates microbial contamination and growth. When biodiesel is compared to distillate fuels, wat 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 biodiese deposits formation therefore these materials must not be used for fuel tanks and fuel lines.

ly recommended that seasonally

ged shutdown periods. An example of

lter. Consult your supplier of fuel for

er is naturally more likely to exist in the

l fuel. The oxidation process can cause

Cooling System Speciﬁcations

General Coolant Information

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

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

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

Coolant i Water, additives, and glycol.

an engine without water temperature

ing temperature. Cooling system prob-

failures are related to the cooling

ugged radiators or heat exchangers.

ntenance. Cooling system maintenance is

as the quality of the fuel and the lubricating

s normally composed of three elements:

Water

Waterisusedinthecoolingsysteminorderto transfe

r heat.

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

NOTICE

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

If the with below freezing temperatures, the cooling system must be either protected to the lowest outside temper-

e or drained completely to prevent damage.

atur

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

an the cooling system for the following reasons:

Cle

Contamination of the cooling system

•

Overheating of the engine

•

aming of the coolant

•

Distilled water or deionized water is recomm

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

If dis use water with the properties that are listed in Table

13.

Tabl

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

ended for use in engine cooling systems.

s: Hard water, softened water that has been

tilled water or deionized water is not available,

e13

ptable Water

Acce

Property Maximum Limit

Chloride (Cl) 40 mg/L

Sulfate (SO4)100mg/L

Total Hardness 170 mg/L

Total Solids 340 mg/L

Acidity pH of 5.5 to 9.0

Local water utility company

•

Agricultural agent

•

Independent laboratory

•

Page 36

36 SEBU8191-01 Maintenance Section Reﬁll Capacities

Additives

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

Corrosion

•

Formation o

•

Rust

•

Scale

•

Foaming of

•

Many additives are depleted during engine operation. These addi

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

Formation of gel compounds

•

Reducti

•

Leakage of the water pump seal

•

Plugging of radiators, coolers, and small passages

•

stem. A lack of coolant additives or

f mineral deposits

the coolant

tives must be replaced periodically.

entration of additives can cause the

on of heat transfer

Table 14

Ethylene Glycol

Concentration

50 Percent −36 °C (−33 °F) 106 °C (223 °F)

60 Percent −51 °C (−60 °F) 111 °C (232 °F)

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 15

Propylene Glycol

Concentration

50 Percent −29 °C (−20 °F) 106 °C (223 °F)

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

Freeze

Protection

NOTICE

Freeze

Protection

Boil

Protection

Anti-Boil

Protection

Coolant Recommendations

The following two coolants are used in Perkins diesel engines:

Glycol

Glycol in the coolant helps to provide protection

st the following conditions:

again

Boiling

•

Freezing

•

tation of the water pump

Cavi

•

For optimum performance, Perkins recommends a

ixture of a water/glycol solution.

1:1 m

Note: Use a mixture that will provide protection

inst the lowest ambient temperature.

aga

Note: 100 percent pure glycol will freeze at a

perature of −13° C (8.6° F).

tem

Most conventional coolants use ethylene glycol.

opylene glycol may also be used. In a 1:1 mixture

Pr with water, ethylene and propylene glycol provide similar protection against freezing and boiling. See

bles 14 and 15.

Preferred – Perkins Extended Life Coolant (ELC)

Acceptable – A commercial heavy-duty coolant that

meets “ASTM D6210” speciﬁcations

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

Perkins recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide optimum heavy-duty performance as a coolant. This ratio may be increased to 1:2 water to glycol if extra freezing protection is required.

A mixture of Supplement Coolant Additive (SCA) and water is acceptable. Perkins recommends a six percent to eight percent concentration of SCA in those cooling systems. Distilled water or deionized water is preferred. Water which has the recommended properties may be used.

Page 37

SEBU8191-01 37

Maintenance Section

Reﬁll Capacities

Engines that ar above 43 °C (109.4 °F) must use SCA and water. Engines that operate in an ambient temperature above 43 °C (10 to seasonal variations consult your Perkins dealer or your Perkins distributor for the correct level of protection.

Table 16

Coolant Type Service Life

Perkins ELC

Commercia

Coolant that meets

“ASTM D6210”

Commercial SCA and

e operating in an ambient temperature

9.4 °F) and below 0 °C (32 °F) due

Coolant Service Life

6,000 Service Hours or

Three Years

lHeavy-Duty

Water

3000 Service Hours or

Two Years

3000 Service Hours or

Two Years

Extended Life Coolant (ELC)

Perkins provides Extended Life Coolant (ELC) for use in the following applications:

Heavy-duty spark ignited gas engines

•

Heavy-duty diesel engines

•

Automotive applications

•

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

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

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

ELC Cooling System M aintenance

Correct additions to the Extended Life Coolant

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

Use only Perkins Extender with Extended Life Coolant.

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

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

Do not use a conventional coolant to top-off a cooling syste

Do not use standard supplemental coolant additive (SCA) are ﬁ lled with ELC.

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.

recommendations can reduce cooling sys-

NOTICE

mthatisﬁlled with Extended Life Coolant (ELC).

. Only use ELC Extender in cooling systems that

NOTICE

After the cooling system is drained and after the cooling system is reﬁlled, operate the engine while the cooling system ﬁller cap is removed. 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.

Page 38

38 SEBU8191-01 Maintenance Section Reﬁll Capacities

Changing to Per

To change from heavy-duty coolant to the Perkins ELC, perform t

Care must be taken to ensure that all ﬂuids are contained d tenance, testing, adjusting and the repair of the product. Be prepared to collect the ﬂuidwithsuitable containers assembling any component containing ﬂuids.

Dispose of mandates.

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to local

regulations.

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

4. Use an appropriate cleaner to clean the system. Follow the instruction on the label.

uring performance of inspection, main-

before opening any compartment or dis-

all ﬂuids according to local regulations and

kins ELC

he following steps:

NOTICE

ELC Cooling Sys

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. Use only Perkins ELC extender with Perkins ELC. Failure to follow these recommendations can result in shortened cooling system component life.

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

Drain the cooling system into a suitable container.

•

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

Drain a portion of the cooling system into a suitable

•

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

tem Contamination

NOTICE

5. Drain the cleaner into a suitable container. Flush the cooling system with clean water.

6. Fill the cooling system with clean water and operate the engine until the engine is warmed to 49° to 6

Incorrect or incomplete ﬂushing of the cooling system can r ponents.

To a v completely ﬂushthecoolingsystemwithclearwater. Continue to ﬂush the system until all the signs of the

aning agent are gone.

cle

7. Drain the cooling system into a suitable container and

Note: The cooling system cleaner must be thoroughly

shed from the cooling system. Cooling system

ﬂu cleaner that is left in the system will contaminate the coolant. The cleaner may also corrode the cooling

stem.

8. Repeat Steps 6 and 7 until the system is

ompletely clean.

9. Fill the cooling system with the Perkins Premixed E

6°C (120° to 150°F).

NOTICE

esult in damage to copper and other metal com-

oid damage to the cooling system, make sure to

ﬂush the cooling system with clean water.

LC.

Maintain the system as a conventional Heavy-Duty

•

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

Commercial Heavy-Duty Coolant and SCA

NOTICE

ercial Heavy-Duty Coolant which contains

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

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

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

Perkins engine cooling systems should be tested at 500 hour intervals for the concentration of Supplemental Coolant Additive (SCA).

Page 39

SEBU8191-01 39

Maintenance Section

Reﬁll Capacities

Additions of SC

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

Adding the SCA t o Heavy-Duty Coolant at the Initial Fill

Use the equation that is in T able 17 to determine the amount of SCA that is required when the cooling system is in

Table 17

Equation For Adding The SCA To The Heavy-Duty

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Table18isanexampleforusingtheequationthat is in Table 17.

Table 18

Example Of The Equation For Adding The SCA To

Total Vo

of the Cooling

System (V)

15L(4USgal)

itially ﬁlled.

Coolant At The Initial Fill

V × 0.045 = X

The Heavy-Duty Coolant At The Initial Fill

lume

Multipl

Factor

×0.045

ication

Amount of SCA

that is Required

(X)

0.7L(24oz)

Table20isanex

ample for using the equation that

is in Table 19.

Table 20

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant For Maintenance

Total Vol u m e

of the Cooling

System (V)

15 L (4 US gal)

Multiplication

Factor

× 0.014

Amount of SCA

that is Required

(X)

0.2 L (7 oz)

Cleaning the System of H eavy-Duty Coolant

Clean the cooling system after used coolant is

•

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

Clean the cooling system whenever the coolant is

•

contaminated or whenever the coolant is foaming.

Adding The SCA to The Heavy-Duty Coolant For Maintenance

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

Test the coolant periodically for the concentration of SCA. For the interval, refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section). Test the concentration of SCA.

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

Use the equation that is in T able 19 to determine the amount of SCA that is required, if necessary:

Table 19

Equation For Adding The SCA To The Heavy-Duty

is the total volume of the cooling system.

X is the amount of SCA that is required.

Coolant For Maintenance

V × 0.014 = X

Page 40

40 SEBU8191-01 Maintenance Section Maintenance Interval Schedule

i03789769

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 43

Battery or Battery Cable - Disconnect .................. 44

Engine - Cle

Engine Air Cleaner Element - Replace ................. 53

Engine Oil Filter (Auxiliary) - Change ................... 55

Engine Oil S

Fuel System - Prime ............................................. 60

Overhaul (Major) ................................................... 65

Overhaul (

Severe Service Application - Check ..................... 67

Daily

Cooling System Coolant Level - Check ................ 52

Driven Equipment - Check .................................... 52

Engine Ai

Engine Oil Level - Check ...................................... 56

Fuel System Primary Filter/Water Separator -

Drain ................................................................... 62

Walk-Around Inspection ........................................ 71

an ...................................................... 53

ample - Obtain .................................. 57

Top End) ............................................... 66

r Cleaner Service Indicator - Inspect ..... 54

Governor Actua

Speed Sensor - Clean/Inspect .............................. 68

tor - Check ................................... 64

Every 5000 Service Hours

Fuel Injector - Inspect/Adjust ................................ 60

Every 7500 Service Hours

Alternator - Inspect ............................................... 42

Engine Oil Pump - Inspect .................................... 56

Fuel Transf

Starting Motor - Inspect ........................................ 69

Turbocharger - Inspect .......................................... 70

Water Pump -

er Pump (Lift Pump) - Inspect ............. 63

Inspect ........................................... 72

Every 12 000 Service Hours or 6 Years

Cooling Sy

stem Coolant (ELC) - Change ............. 47

Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 62

Initial 100 Service Hours

Alternator Pulley - Check ...................................... 42

Engine Valve Lash - Inspect/Adjust ...................... 59

Fan Dr

ive Pulley - Check ...................................... 59

Every 500 Service Hours

e Oil Filter (Auxiliary) - Change ................... 55

Engin

Engine Oil and Filter - Change ............................. 57

Every 500 Service Hours or 1 Year

Actuator Control Linkage - Lubricate .................... 41

Aftercooler Core - Clean/Test ............................... 41

rcooler Core - Inspect ..................................... 42

Afte

Battery Electrolyte Level - Check .......................... 43

Belts - Inspect/Adjust/Replace .............................. 44

ts - Inspect/Adjust/Replace .............................. 46

Bel

Engine Crankcase B reather - Clean ..................... 54

Engine Valve Lash - Inspect/Adjust ...................... 59

l System Filter - Replace ................................ 61

Fue

Hoses and Clamps - Inspect/Replace .................. 64

Radiator - Clean .................................................... 67

ery Year

Cooling System Coolant - Change ....................... 49

gine Mounts - Inspect ....................................... 55

Engine Protective Devices - Check ...................... 59

Page 41

SEBU8191-01 41

Maintenance Section

Actuator Control Linkage - Lubricate

Actuator Control Linkage Lubricate

Illustration 26

Typical example

i02471679

g01238418

i02415235

Aftercooler Core - Clean /Test

1. Remove the cor

for the correct procedure.

Personal injury can result from air pressure.

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

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

2. Pressurized air is the preferred method for

removing loose debris. Direct the air in the opposite direction of the fan's air ﬂow. Hold the nozzle approximately 6 mm (.25 inch) away from the ﬁns. Slowly move the air nozzle in a direction that is parallel with the tubes. This will remove debris that is between the tubes.

e. Refer to the OEM information

Illustration 27

Typical example

g01242298

The governor actuator (3) is connected to the fuel injectors by external linkages (1) and by internal control rods.

The linkages (1) require periodic lubrication of the ball joints (2). Use clean engine oil in order to lubricate the ball joints.

3. 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 thecorefrombothsides.

NOTICE Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner.

4. Back ﬂush the core with a suitable cleaner.

5. Steam clean the core in order to remove any

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

6. Wash the core with hot, soapy water. Rinse the

core thoroughly with clean water.

Page 42

42 SEBU8191-01 Maintenance Section Aftercooler Core - Inspect

Personal injury can result from air pressure.

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

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

7. Dry the core with compressed air. Direc t the air in

the reverse direction of the normal ﬂow.

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

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

10. After cleaning, run the engine. This will help in the removal of debris and drying of the core. Stop the engine.

i024152

Aftercooler Core - Inspect

Note: A

the effects of the operating environment.

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

djust the frequency of cleaning according to

ct the aftercooler for these items: damaged ﬁns,

Note: If parts o

f the aftercooler system are repaired

or replaced, a leak test is highly recommended.

Inspect these

items for good condition: Welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.

i02322311

Alternator - Inspect

Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and correct battery charging. Check the ammeter (if equipped) during engine operation in order to ensure correct battery performance and/or correct performance of the electrical system. Make repairs, as required.

Check the alternator and the battery charger for correct operation. If the batteries are correctly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature

affects the cranking power. If the battery is too cold, the battery will not crank the engine. When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge.

3737

i0246

Alternator Pulley - Check

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

sonal injury can result from air pressure.

Per

Personal injury can result without following prop-

rocedure. When using pressure air, wear a pro-

er p tective face shield and protective clothing.

ximum air pressure at the nozzle must be less

Ma than 205 kPa (30 psi) for cleaning purposes.

ter cleaning, start the engine and run the engine.

Af This will help in the removal of debris and drying of the core. Stop the engine.

Inspect the ﬁns for damage. Bent ﬁns may be opened with a “comb”.

ate the electrical supply to the engine.

1. Isol

Illustration 28

Typical exa mple

g01237956

2. Remove the guard (3) in order to gain access to

the drive pulley (1) for the alternator (2).

Page 43

SEBU8191-01 43

Maintenance Section

Battery - Replace

Illustration 29

Typical example

3. Tighten the grub screws (4) to a torque of 20 N·m (15 lb ft).

4. Install the guard (3).

5. Restore the electrical supply to the engine.

g01233693

i023223

Battery - Replace

2. Turn off any bat

battery chargers.

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

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

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

5. Remove the used battery.

6. Install the new battery.

Note: Bef

theenginestartswitchisOFF.

7. Connect t

8. Connect

facility.

ore the cables are connected, ensure that

POSITIVE “+” battery terminal.

theNEGATIVE“-”cabletotheNEGATIVE

“-” battery terminal.

tery chargers. Disconnect any

-” cable connects the NEGATIVE

“-” battery termi nal.

terminal to the POSITIVE “+” terminal

he cable from the starting motor to the

i02747977

Batteries give off combustible gases which can explode. A spark can cause the combustible gas-

gnite. This can result in severe personal in-

es to i jury or death.

re proper ventilation for batteries that are in

Ensu an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks

batteries. Do not smoke when batteries are

near serviced.

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

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

1. Switch the engine to the OFF position. Remove

all electrical loads.

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.

Page 44

44 SEBU8191-01 Maintenance Section Battery or Battery Cable - Disconnect

2. Check the condi suitable battery tester.

3. Install the ca

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.

•

Thoroughl

tion of the electrolyte with a

ps.

y rinse the battery case with clean water.

Battery or Battery Cable Disconnect

i02323088

7. Proceed with ne

8. In order to connect the battery, connect the

positive conn

cessary system repairs.

ection before the negative connector.

i03755297

Belts - Inspect/Adjust/Replace (Fan Drive Belts)

Inspection

1. Isolate the electrical supply to the engine.

2. Loosen the fasteners for the air pipes (not shown).

3. Remove the guards (not shown).

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

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

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

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

2. Disconnect the negative battery terminal. Ensure that the cable cannot contact the terminal. When four 12 volt batteries are involved, two negative connection 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 ofmaterialcancausetheclampstonotﬁt correctly. Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly.

Illustration 30

4. Inspect the belts (1) for cracks. Inspect the belts for contamination. If necessary, replace the belts. Refer to “Replacement” for more information.

5. The belt tension must be checked at position A. Use a suitable spring balance and a suitable straight edge in order to check the belt tension.

6. The belt tension should be 62 N (14 lb) with a maximum deﬂection at position B of 16 mm (0.63 inch).

7. Adjust the belts if the belt tension exceeds 62 N (14 lb). Refer to “Adjustment” for more information.

g02025316

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

8. Tighten the fasteners for the air pipes (not shown) to a torque of 120 N·m (88.5 lb ft).

Page 45

SEBU8191-01 45

Maintenance Section

Belts - Inspect/Adjust/Replace

9. Install the gua

10. Restore the electrical supply to the engine.

rds (not shown).

Adjustment

1. If necessary, isolate the electrical supply to the

engine. Loosen the fasteners for the air pipes and remove the gu

ards.

Removal of the F

Illustration 32

Typical exa mple

1. If necessary, isolate the electrical supply to the engine. Loosen the fasteners for the air pipes and remove the guards.

an Drive Belts

g01239588

Illustration 31

2. Loosen the locknut (4).

3. Rotate the rod (3) in order to achieve the correct

tension of belts (1). Refer to “Inspection” for the correct speciﬁcation.

4. Tighten the locknut (4) to a torque of 120 N·m (88.5lbft).

5. If necessary, restore the electrical supply to the engine. Tighten the fasteners for the air pipes and install the guards.

g01239588

Replacement

Note: Fan drive belts must be replaced as a set. Do

not replace individual belts.

2. Loosen the locknut (4).

3. Rotate the rod (3) until the pulley (2) is toward the

center of the engine.

4. Remove the belts (1).

Installation of the Fan Drive Belts

1. Install new belts (1) over the pulleys.

2. Rotate the rod (3) in order to achieve an initial

tension of 77 N (17 lb). The total deﬂection should not exceed 16 mm (0.63 inch).

3. Tighten the locknut (4) to a torque of 120 N·m (88.5lbft).

4. Rotate the pulleys for the fan drive belts three to four revolutions in order to ensure that the fan drive belts are correctly installed. Ensure that the tension is still 77 N (17 lb).

5. If necessary, restore the electrical supply to the engine. Tighten the fasteners for the air pipes and install the guards.

6. Operate the engine for 15 to 20 minutes. Refer to Operation and Maintenance Manual, “Starting the Engine” for the correct procedure.

Page 46

46 SEBU8191-01 Maintenance Section Belts - Inspect/Adjust/Replace

7. Stop the engine Maintenance Manual, “Stopping the Engine” for the correct procedure.

8. If necessary, isolate the electrical supply to the engine. Loosen the fasteners for the air pipes and remove the gu

9. Loosen the locknut (4).

10. Rotate the rod (3) in order to achieve a ﬁnal

tension of 62 N (14 lb). The total deﬂection should not exceed 1

11. Tighten the locknut (4) to a torque of 120 N·m (88.5lbft

12. If necessary, restore the electrical supply to the engine. Ti install the guards.

. Refer to Operation and

ards.

6 mm (0.63 inch).

ghten the fasteners for the air pipes and

i03104621

Belts - Inspect/Adjust/Replace (Alternator Belt)

Illustration 34

4. Apply 15.6 N (3.5 lb) of pressure at point (X).

The total deﬂection should not exceed 1.5 mm (0.06 inch).

Replace the belt if the total deﬂection exceeds

1.5 mm (0.06 inch). Refer to “Replacement” for more information.

5. Install the guard (3) and bolts (2).

6. Restore the electrical supply to the engine.

g01239310

Inspection

1. Isolate the electrical supply to the engine.

Illustration 33

pical example

2. Remove the bolts (2) and remove the guard (3).

3. Inspect the belt (1) for cracks. Inspect the belt

for contamination. If necessary, replace the belt.

efer to “Replacement” for more information.

g01233715

Adjustment

The alternator belt is a toothed belt. The belt tension is not adjustable. The belt does not require a preload. Light tension will ensure that the belt is a snug ﬁton the pulleys.

Replacement

Removal of the Alternator Belt

1. If necessary, Isolate the electrical supply to the

engine and remove the guards.

Page 47

SEBU8191-01 47

Maintenance Section

Cooling System Coolant (ELC) - Change

i03845643

Cooling System Co ola nt (ELC)

-Change

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

Dispose of all ﬂuids according to Local regulations and mandates.

NOTICE

Illustration 35

Typical example

2. Remove nut (5) and bolt (4).

3. Loosen nut (7) and push the alternator (6) toward

the engine.

g01239580

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

4. Remove the belt (1).

Installation of the Alternator Belt

1. Install the belt (1) over the pulleys.

Note: Ensure that the teeth on the belt are engaged

with the teeth on the pulleys.

2. Pull the alternator (6) away from the engine. Install bolt (4) and nut (5).

3. Tighten nuts (5) and (7).

4. Check the tension of the belt. Refer to “Inspection”

for the correct procedure.

5. If necessary, restore the electrical supply to the engine and install the guards.

The engine overheats frequently.

•

Foaming of the coolant is observed.

•

The oil has entered the cooling system and the

•

coolant is contaminated.

The fuel has entered the cooling system and the

•

coolant is contaminated.

Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced.

Note: Inspect the water pumps and the water temperature regulators after the cooling system has been drained. This is a good opportunity to replace the water pumps, the water temperature regulators, and the hoses, if necessary.

Drain

Page 48

48 SEBU8191-01 Maintenance Section Cooling System Coolant (ELC) - Change

Illustration 36

Typical example

g01211179

1. Stop the engine and allow the engine to cool. Loosen the cooling system ﬁller cap (1) slowly in order to relieve any pressure. Remove the cooling system ﬁller cap.

4. Open the drain c (3) in the oil coolers.

Illustration 39

Typical exa mple

ocks or remove the drain plugs

g02091597

Illustration 37

Typical example

2. Open

the drain cock or remove the drain plug (2)

in the cylinder block.

3. Open

the drain cock or remove the drain plug on

the radiator.

g0121

116 0

5. Open the drain cocks or remove the drain plugs (5) in the aftercoolers.

6. Allow the coolant to drain.

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

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

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

2. Close the drain cock or install the drain plug (2)

in the cylinder block. Close the drain cock or install the drain plug on the radiator. Close the drain cocks or install the drain plugs (3) in the oil coolers. Close the drain cocks or install the drain plugs (5) in the aftercoolers.

Illustration 38

Typical example

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

g01211161

Cooling system air locks may result in engine damage.

Page 49

SEBU8191-01 49

Maintenance Section

Cooling System Coolant - Change

3. Fill the coolin

If equipped, loosen the vent screws (4) in the aftercoolers free of air ﬂows from the vent screws. Tighten the vent screws securely.

Install the cooling system ﬁller cap (1).

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

5. Stop the eng Loosen the cooling system ﬁller cap (1) slowly in order to relieve any pressure. Remove the cooling system ﬁll the drain plug (2) in the cylinder block. Open the drain cock or remove the drain plug on the radiator. plugs (3) in the oil coolers. Open the drain cocks or remove the drain plugs (5) in the aftercoolers. Allow the with clean water.

g system with clean water.

. Fill the cooling system until coolant

gine. Run the engine until the

ine and allow the engine to cool.

er cap. Open the drain cock or remove

Open the drain cocks or remove the drain

watertodrain.Flushthecoolingsystem

Fill

Illustration 40

Typical exa mple

5. Clean the cooling system ﬁller cap (1) and inspect the seal (2). If the seal is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the seal 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, replace the ﬁller cap.

Install the cooling system ﬁller cap.

6. Start the engine and run the engine. Inspect the cooling system for leaks. Ensure that the cooling system operates at the correct temperature.

g01239656

1. Close th in the cylinder block. Close the drain cock or install the drain plug on the radiator. Close the drain co coolers. Close the drain cocks or install the drain plugs (5) in the aftercoolers.

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

Cooling system air locks may result in engine damage.

2. Fill Coolant (ELC). Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topi on cooling system speciﬁcations. Do not install thecoolingsystemﬁller cap (1).

3. Start the engine. Run the engine in order to purge the air from the cavities of the engine block. Stop the

4. Check that the coolant level is within 25 mm (1

e drain cock or install the drain plug (2)

cks or install the drain plugs (3) in the oil

NOTICE

the cooling system with Extended Life

c (Maintenance Section) for more information

engine.

.0 inch) of the bottom of the ﬁller pipe.

i04328029

Cooling System Coolant Change (Inhibitor)

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.

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

The engine overheats frequently.

•

Foaming of the coolant is observed.

•

Page 50

50 SEBU8191-01 Maintenance Section Cooling System Coolant - Change

The oil has ente

•

red the cooling system and the

coolant is contaminated.

The fuel has en

•

tered the cooling system and the

coolant is contaminated.

Note: When th

e cooling system is cleaned, only clean water is needed when the inhibitor is drained and replaced.

Note: Inspect the water pumps and the water temperature regulators after the cooling system has been draine

d. This is a good opportunity to replace the water pumps, the water temperature regulators, and the hoses, if necessary.

Drain

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

ngine and wait until the cooling system

Illustration 42

Typical exa mple

g0 1 21116 0

2. Open the drain cock or remove the drain plug (2) in the cylinder block.

3. Open the drain cock or remove the drain plug on the radiator.

stration 41

Illu

Typical example

g01211179

1. Stop the engine and allow the engine to cool. Loosen the cooling system ﬁller cap (1) slowly in

er to relieve any pressure. Remove the cooling

ord system ﬁller cap.

Illustration 43

Typical exa mple

4. Open

the drain cocks or remove the drain plugs

(3) in the oil coolers.

g0121

116 1

Page 51

SEBU8191-01 51

Maintenance Section

Cooling System Coolant - Change

Illustration 44

Typical example

g01239623

5. Open the drain cocks or remove the drain plugs (5) in the aftercoolers.

6. Allow the coolant to drain.

NOTICE Dispose of all ﬂuids according to local regulations and mandates. When you recycle used engine coolant for reuse in engine cooling systems, the full distillation procedure is the only method acceptable by Perkins Engines Company LTD to reclaim the coolant.

If equipped, lo

osen the vent screws (4) in the aftercoolers. Fill the cooling system until coolant free of air ﬂows from the vent screws. Tighten the vent screws se

curely.

Install the cooling system ﬁller cap (1).

4. Start the engine. Run the engine until the temperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool. Loosen the cooling system ﬁller cap (1) slowly in order to rel

ieve any pressure. Remove the cooling system ﬁller cap. Open the drain cock or remove the drain plug (2) in the cylinder block. Open the drain c

ock or remove the drain plug on the radiator. Open the drain cocks or remove the drain plugs (3) in the oil coolers. Open the drain cocks or remove t

he drain plugs (5) in the aftercoolers. Allow the water to drain. Flush the cooling system with clean water.

Fill

1. Close the drain cock or install the drain plug (2)

in the cylinder block. Close the drain cock or

the drain plug on the radiator. Close the

install drain cocks or install the drain plugs (3) in the oil coolers. Close the drain cocks or install the drain plugs (5

Do not ﬁll the cooling system faster than 5 L (1.3 US

Cooling system air locks may result in engine damage.

) in the aftercoolers.

NOTICE

gal) per minute to avoid air locks.

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

2. Close the drain cock or install the drain plug (2) in the cylinder block. Close the drain cock or install the drain plug on the radiator. Close the drain cocks or install the drain plugs (3) in the oil coolers. Close the drain cocks or install the drain plugs (5) in the aftercoolers.

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

Cooling system air locks may result in engine damage.

3. Fill the cooling system with clean water.

2. Fill the cooling system with water and inhibitor.

Refer to the Operation and Maintenance Manual,

id Recommendations” topic (Maintenance

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

r cap (1).

ﬁlle

3. Start the engine. Run the engine in order to purge air from the cavities of the engine block. Stop

the the engine.

4. Che

ck that the coolant level is within 25 mm

(1.0 inch) of the bottom of the ﬁller pipe.

Illustration 45

g01239656

Page 52

52 SEBU8191-01 Maintenance Section Cooling System Coolant Level - Check

5. Clean the cooli the seal (2). If the seal is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the seal is not damaged in order to pressure test the ﬁller cap. The correct pressure is stamped on the face of the ﬁller cap. If the ﬁller cap replace the ﬁller cap.

Install the

6. Start the engine and run the engine. Inspect the cooling sys system operates at the correct temperature.

ng system ﬁller cap (1) and inspect

,useasuitablepressurizingpump

does not retain the correct pressure,

cooling system ﬁller cap.

tem for leaks. Ensure that the cooling

i02415245

Cooling System Coolant Level

- Check

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

Illustration 47

3. Clean the cooling system ﬁller cap (1) and inspect the seal (2). If the seal is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the seal 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, replace the ﬁller cap.

Install the cooling system ﬁller cap.

4. Inspect the cooling system for leaks.

g01239656

i02151646

Driven Equipment - Check

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

Inspection

•

lustration 46

1. Remove the cooling system ﬁller cap (1) slowly in der to relieve pressure.

2. Maintain the coolant level within 25 mm (1.0 inch)

f the bottom of the ﬁller pipe.

g01211179

Adjustment

•

Lubrication

•

Other maintenance recommendations

•

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

Page 53

SEBU8191-01 53

Maintenance Section

Engine - Clean

i02415247

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 OPERAT

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

Water or condensation can cause damage to generator components. Protect all electrical components from ex

Failu washing may make your engine warranty invalid. Allow the engine to cool for one hour before washing the e

posure to water.

re to protect some engine components from

ngine.

E”.

NOTICE

i03781630

Engine Air Cleaner Element 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.

Renew the air ﬁlter elements if the service indicators are triggered. Refer to Operation and Maintenance Manual, Inspect” for more information.

Some en precleaners. Clean the precleaners before maintenance is performed on the air ﬁlters. Ensure that di

“Engine Air cleaner Service Indicator -

gines are equipped with air intake

rt does not enter the housing of the air cleaner.

Periodic cleaning of the engine is recommended. A

n engine provides the following beneﬁts:

clea

Easy detection of ﬂuid leaks

•

Maximum heat transfer characteristics

•

e of maintenance

Eas

•

Note: Cautionmustbeusedinordertoprevent

ectrical components from being damaged by

el excessive water when the engine is cleaned. Pressure washers and steam cleaners should not be

rected at any electrical connectors or the junction

di of cables into the rear of the connectors. Avoid electrical components such as the alternator, the

tarting motors, and the ECU.

Illustration 48

1. Loosen securing clamp (3) and remove cover (4)

for housing (1).

2. Remove the old element (2) from the housing (1).

Discard the old element.

Note: Ensure that dirt does not enter the housing.

g02041513

Page 54

54 SEBU8191-01 Maintenance Section Engine Air Cleaner Service Indicator - Inspect

3. Install a new el Install the cover (4) and tighten securing clamp (3).

ement (2) into the housing (1).

i02415251

Engine Air Cleaner Service Indicator - Inspect

Service Indicator Check

Check the service indicators. Replace the air ﬁlter elements if one of service indicators has been triggered.

Service Indicator Reset

ion 51

Illustrat

Once the service indicator has been triggered and when the a service indicator must be reset. In order to reset the service indicator (1), press the button (2).

If the service indicator does not reset easily, the service indicator should be replaced.

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

ir ﬁlter element has been replaced, the

g01242328

tration 49

Illus

When the air ﬁlter element is in a serviceable

tion, the center section of the service indicator

condi (1) is clear.

Illustration 50

When the air ﬁlter element requires replacement, the center section of the service indicator (1) is red.

g01242320

g01242332

i04631326

Engine Crankcase Breather Clean

The engine crankcase breathers are mounted on the side of the water regulators.

1. Isolate the electrical supply to the starting motor.

Page 55

SEBU8191-01 55

Maintenance Section

Engine Mounts - Inspect

Loose bolts

•

Deterioration of the isolators

•

Ensure that the mounting bolts are tightened to the correct torque.

Ensure that the isolators are free of oil and contamination. Inspect the isolators for deterioration. Ensure that the correct torque.

the bolts for the isolators are tightened to

Illustration 52

Typical example

2. Remove the wing nut (1) and the cover (2).

3. Remove the ﬁlter elements (3) from the breather

body (5).

4. Clean the ﬁlter elements (3) and dry the ﬁlter elements. Inspect the ﬁlter elements for damage or deterioration. If necessary, replace the ﬁlter elements.

5. Install the ﬁlter elements (3) to the breather body (5).

6. Ensure that the seal in the cover (2) is free from damage. If necessary, replace the seal.

g02775881

Replace any more information, see the literature that is provided bytheOEMoftheisolators.

isolator that shows deterioration. For

i04631322

Engine Oil Filter (Auxiliary) Change

Note: Refer to the Operation and Maintenance

Manual, “Engine Oil Sample - Obtain” before performing maintenance.

Change the Filter with t he Engine in Operation

l and hot components can cause personal

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

7. Align the cover (2) with the dowel (4). Install the

cover to the breather body (5).

8. Install the wing nut (1). Tighten the wing nut securely.

9. Restore the electrical supply to the starting motor.

i02415257

Engine Mounts - Inspect

Misalignment of the engine and the driven equipment will cause extensive damage. Excessive vibration can lead to misalignment. Excessive vibration of the engine and the driven equipment can be caused by the following conditions:

Improper mounting

•

Illustration 53

Typical exa mple

g02775859

Page 56

56 SEBU8191-01 Maintenance Section Engine Oil Level - Check

The changeover

(A) The oil ﬂow is to both oil ﬁlters.

•

(B) The oil ﬂow is to the left-hand oil ﬁlter.

•

valve (1) has three positions.

w is to the right-hand oil ﬁlter.

1. Rotate the changeover valve to position B. By usingasuit

able tool (2), remove the right-hand

oil ﬁlter.

Note: Oil ﬂo

w direction (D and E ).

2. Ensure that the sealing face on the housing is clean. Fil

l the new oil ﬁlter with clean engine oil. Install the new oil ﬁlter. Rotate the changeover valve to position A. Check for oil leaks.

3. Rotate the changeover valve to position C. By using a suitable tool, remove the left-hand oil ﬁlter.

4. Ensure that the sealing face on the housing is clean. Fill the new oil ﬁlter with clean engine oil. Install t

he new oil ﬁlter. Apply hand pressure only in order to install the oil ﬁlter. Rotate the changeover valve to position A. Check for oil leaks.

Illustration 54

g01236968

5. Clean any spillage of engine oil.

i02415261

Engine Oil Level - Ch eck

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

NOTICE

form this maintenance with the engine stopped.

Per

Note: After the engine has been switched OFF, wait

r ten minutes in order to allow the engine oil to drain

fo to the oil pan before checking the oil level.

NOTICE

perating your engine when the oil level is above the

O “Max” mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft

ipping into the oil reduces the oil's lubricating char-

d acteristics and could result in the loss of power.

Illustration 55

(Y) “ Min” mark. (X) “Max” mark.

g01165836

1. Maintain the oil level between the “Min” mark (Y) and the “Max” mark (X) on the engine oil level gauge (2). Do not ﬁll the oil pan above the “Max” mark (X).

2. If necessary, remove the oil ﬁller cap (1) and add oil. Clean the oil ﬁller cap. Install the oil ﬁller cap.

i02471700

Engine Oil Pump - Inspect

A failed engine oil pump may result in a seizure of the crankshaft.

Remove the engine oil pump and disassemble the engine oil pump. Refer to Operation Manual TSL4165 for more information. Inspect the components of engine oil pump for wear and for damage. Refer to Operation Manual TSL4165 for more information. Replace any components that are worn or damaged. Alternatively, replace the engine oil pump.

Page 57

SEBU8191-01 57

Maintenance Section

Engine Oil Sample - Obtain

i02415262

Engine Oil Sample - Obta in

The condition of the engine lubricating oil should be checked at regular intervals as part of the preventive maintenance

Initiating

The First 500 Hours

Oil analysis in the ﬁrst 500 hours will show higher levels of iron and copper than acceptable parameters. As the engi drop within the speciﬁed parameters.

Every 250

An oil sample should be obtained at 250 hour interval

A trend can be established by analyzing the results of the oi develop a service program for the engine.

program.

an Oil analysis Program

ne continues to operate the levels will

Hours

l sampling. Each individual operator can

The amount of oi

•

last oil change

Ensure that th 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 supp samples must be clean.

The sample quality of the oil, the existence of any coolant in the oil, the existence of any ferrous metal particles in the oil, an particles in the oil.

d the existence of any nonferrous metal

Engine O

l that has been added since the

e container for the sample is clean and

lies that are used for obtaining oil

can be checked for the following: the

i04631317

il and Filter - Change

Note: Pe

maintenance schedule.

rkins Engines Stafford must agree to the

Obtain the Sample and the Analysis

Hot oil and hot components can cause personal

y. Do not allow hot oil or hot components to

injur contact the skin.

il sample must be taken from the mean level in

The o the engine oil pan. Do not take an oil sample from the drain plug.

In order to help obtain the most accurate analysis, record the following information before an oil sample

aken:

is t

Thedateofthesample

•

Engine model

•

gine number

•

Service hours on the engine

•

The number of hours that have accumulated since

•

the last oil 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

ng performance of inspection, maintenance, test-

duri ing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before open-

ny compartment or disassembling any compo-

ing a nent containing ﬂuids.

ose of all ﬂuids according to local regulations and

Disp 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

ngine is cold. As the engine lubricating oil cools,

e suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed with

rainingcoldoil.Draintheoilpanwiththeengine

d 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.

Page 58

58 SEBU8191-01 Maintenance Section Engine Oil and Filter - Change

Failuretofoll

ow this recommended procedure will cause the waste particles to be recirculated through theenginelubricationsystemwiththenewoil.

Drain the Engine Lubricating Oil

Illustration 56

Typical example

1. Place a suitable container below the engine oil

pan. Remove the drain plug (3). Allow the engine oil to drain.

Note: Ensure that the vessel that will be used is large enough to collect the waste oil.

2. Remove the sealing washer from the drain plug

(3). Discard the sealing washer.

3. Install a new sealing washer to the drain plug (3).

Install the drain plug to the engine oil pan. Tighten the plug to a torque of 68 N·m (50 lb ft).

g01237431

Illustration 57

Typical exa mple

g02775854

1. Use Tooling (A) in order to remove the oil ﬁlters (4).

2. Ensure that the sealing face of the ﬁlter base (6)

is clean.

3. Lubricate the sealing rings (5) with clean engine oil. Fill the oil ﬁlters with clean engine oil. Ensure that the engine oil that is added to the oil ﬁlters has not been contaminated. Install the new oil ﬁlters (4).

Note: Apply hand pressure only in order to tighten the oil ﬁlters.

Replace the Oil Filter

Table 21

Required Tools

Tool

Perkins oil ﬁlters are manufactured to Perkins Engine Company LTD speciﬁcations.Useofanoilﬁlter that is not recommended by Perkins Engine Company LTD could result in severe damage to the engine. Large particles from unﬁltered engine oil will cause damage to the engine. Do not use oil ﬁlters that are not recommended by Perkins Engine Company LTD.

Note: All six oil ﬁlters must be changed as a set.

Part

Number

Part Name Qty

Strap Wrench 1

NOTICE

Fill the Oil Pan

Refer to Operation and Maintenance Manual, “Fluid Recommendations” for information on suitable oils.

1. Remove the oil ﬁller cap.

2. Fill the oil pan with the correct amount of new

engine lubricating oil. Refer to Operation and Maintenance Manual, “Reﬁll Capacities” for more information.

NOTICE If equipped with an auxiliary oil ﬁlter system or a remote ﬁlter system, follow the OEM or the ﬁlter manufacture's recommendations. Under ﬁlling or over ﬁlling the crankcase with oil can cause engine damage.

Note: Before starting the engine, crank the engine on the starter in order to obtain oil pressure.

Page 59

SEBU8191-01 59

Maintenance Section

Engine Protective Devices - Check

3. Start the engin Perform this procedure in order to ensure that the lubrication system has oil and that the oil ﬁlters are ﬁlled. Ins

4. Stop the engine and allow the oil to drain back to the oil pan fo

Illustration 58

” m ark. (X) “Max” mark.

(Y) “Min

5. Remove the engine oil level gauge (2) in order to check th the “MIN” and “MAX” marks on the engine oil level gauge.

e and run the engine for 2 minutes.

pect the oil ﬁlters for oil leaks.

r a minimum of 10 minutes.

g01165836

e oil level. Maintain the oil level between

i02461963

To prevent dama service personnel or your Perkins dealer should perform the tests.

ge to the engine, only authorized

Visual Inspection

Visually check the condition of all gauges, sensors and wiring. Look for wiring and components that are loose, br or components should be repaired or replaced immediately.

oken, or damaged. Damaged wiring

i03783789

Engine Valve Lash Inspect/Adjust (Valves and Valve Bridges)

NOTICE Only qualiﬁ ed 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.

Engine Protective Devices Check

Alarms and shutoffs must function properly. Alarms provide timely warning to the operator. Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine protective devices are in good working order during normal operation. Malfunctions must be simulated in order to test the engine protective devices.

A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints. Ensure that the engine protective devices are functioning properly.

NOTICE During testing, abnormal operating conditions must be simulated.

The tests must be performed correctly in order to prevent possible damage to the engine.

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.

Note: The valve bridges must be equalized before the valve lash is adjusted.

Refer to Systems Operation, Testing and Adjusting, “V alve Lash - Adjust” for the correct procedure.

i02463729

Fan Drive Pulley - Check

1. Isolate the electrical supply to the engine.

Page 60

60 SEBU8191-01 Maintenance Section Fuel Injector - Inspect/Adjust

i03783899

Fuel Injector - Inspect/Adjust

NOTICE

Only qualiﬁed service personnel should perform this

e. Refer to the Service Manual or your au-

ency, and also reduce engine component

ector Adjustment” for the correct procedures

i02415266

Illustration 59

Typical example

2. Remove the guards (not shown) in order to gain

access to the fan drive pulley (1).

g01238304

maintenanc thorized Perkins distributor for the complete procedure in order to inspect or adjust the fuel injectors.

Operation of Perkins engines with fuel injectors that have not been inspected or adjusted can reduce engine efﬁci life.

Refer to Systems Operation, Testing and Adjusting, “Fuel Inj to inspect and adjust the fuel injectors.

Fuel System - Prime

Illustration 60

3. Tighten the grub screws (2) to a torque of 90 N·m

(66 lb ft).

4. Install the guards (not shown).

5. Restore the electrical supply to the engine.

g01238305

If air enters the fuel system, the air must be purged from the fuel system before the engine can be started. Air can enter the fuel system when the following events occur:

Thefueldaytankisemptyorpartiallydrained.

•

The low pressure fuel lines are disconnected.

•

A leak exists in the low pressure fuel system.

•

The fuel ﬁlter has been replaced.

•

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

Note: Do not bleed the fuel system from the water separator (if equipped).

1. Ensure that the fuel system is in working order. Check that the fuel supply from the fuel day tank is in the “ON” position.

Page 61

SEBU8191-01 61

Maintenance Section

Fuel System Filter - Replace

Illustration 61

Typical example

g01280510

2. Place a suitable container below the tee piece (2) in order to catch any fuel that might be spilled.

8. Operate the han

dle (4) until fuel that is free of air

ﬂows from the connection (5).

9. Tighten the co

nnection (5).

10. Loosen connections (6) and (8).

11. Operate the handle (4) until fuel that is free of air

ﬂows from the connection (6) and (8).

12. Tighten connections (6) and (8).

One cylinde

r is now primed. An amount of fuel will

have reached the remaining cylinders.

13. Push the ha

ndleandtwistthehandleinorderto

return the priming pump to the locked position.

14. Operate th

e starting motor and crank the engine. After the engine has started, run the engine for a minimum of ﬁve minutes.

Note: Operating the engine for this period of time will purge the remaining air from the fuel system.

i03791032

Note: Clean up any spillage of fuel immediately.

3. Loosen the connection (1) at the tee piece (2).

4. Unscrew the handle (4) in order to operate the fuel

priming pump (3). Pump the handle until fuel that is free of air ﬂows from the tee piece (2).

5. Tighten the connection (1) on the tee piece (2).

Illustration 62

Typical example

g01237503

Fuel System 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. Cleanupfuelspillsimmediately.

NOTICE

Ensure that the engine is stopped before any servicing

pair is performed.

or re

Fuel Filter with Water Separator

Table 22

Required Tools

Too l

Part

Number

Part Name

Strap Wrench 1

Qty

6. Place a suitable container below the rear of the

fuel rail (7) on A bank, in order to catch any fuel that might be spilled.

Note: Clean up any spillage of fuel immediately.

7. Loosen the connection (5).

1. Isolate the fuel supply to the engine.

2. Place a suitable container under the fuel ﬁ lter in

order to catch any fuel that might spill.

Note: Clean up any spilled fuel immediately.

Page 62

62 SEBU8191-01 Maintenance Section Fuel System Primary Filter/Water Separator - Drain

NOTICE Ensure that th or repair is performed.

The water separator can be under suction during normal engine operation. Ensure that the drain valve is tightened s the fuel system.

e engine is stopped before any servicing

NOTICE

ecurely to help prevent air from entering

Illustration 63

Typical example

3. Loosen the drain plug (2). Allow the ﬂuidtodrain into the container.

4. Clean the outside of the fuel ﬁlter. Use Tooling (A) in order to remove the canister (1). Dispose of the canister in accordance with local regulations.

5. Lubricate the O ring seal on the new canister with clean fuel oil. Install the new canister. Tighten the canister by hand.

6. Tighten the drain plug (2). Use hand pressure only.

7. Remove the container and dispose of the fuel in

accordance with local regulations.

8. Restore the fuel supply to the engine.

9. Prime the fuel system. Refer to the Operation and

Maintenance Manual, “Fuel System - Prime” for more information.

10. Start the engine and run the engine. Check the fuel system for leaks.

g02775756

15268

i024

Fuel System Primary

ter/Water Separator - Drain

Fil

1. Place a sui

separator in order to catch any fuel that might spill.

Note: Clea

Illustration 64

Typical exa mple

2. Loosen the drain plug (1). Allow the ﬂuid to drain into the container until clean fuel can be seen.

3. Tighten the drain plug (1). Use hand pressure only. Dispose of the drained ﬂuidinaccordance with local regulations.

table container under the water

n up any spilled fuel immediately.

g01237449

i02335436

Fuel Tank Water and Sediment

-Drain

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

Dispose of all ﬂuids according to local regulations and mandates.

Page 63

SEBU8191-01 63

Maintenance Section

Fuel Transfer Pump (Lift Pump) - Inspect

Fuel Tank

Fuel quality i 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 tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from re in the fuel.

s critical to the performance and to the

fuel system and the fuel returns to the

liable sources can help to eliminate water

Drain the Water and the Sediment

Fuel tanks 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 drai

Check the fuel daily. Allow ﬁve minutes after the fuel tan sediment from the fuel tank.

should contain some provision for draining

nvalve.

k has been ﬁlled before draining water and

If a bulk storag recently, allow adequate time for the sediment to settle before ﬁlling the engine fuel tank. Internal bafﬂes in the b sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel. When possibl

e tank has been reﬁlled or moved

ulk storage tank will also help trap

e, water separators should be used.

i02471681

Fuel Transfer Pump (Lift Pump)

-Inspect

Visually inspect the lift pump for leaks. The lift pump is not a serviceable item. Replace a lift pump that is faulty. R

Replacem

Removal of the Lift Pump

1. Isolate the fuel supply to the lift pump.

2. Placeas

Note: C

eplace a lift pump that leaks.

ent of the Lift Pum p

uitable container below the lift pump in

order to catch any fuel that might be spilled.

lean up any spillage of fuel immediately.

e fuel tank after operating the engine in

Fill th order to drive out moist air. This will help prevent condensation. Do not ﬁll the tank to the top. The

pands as the fuel gets warm. The tank may

fuel ex overﬂow.

Some f and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take f the engine is equipped with this system, regular maintenance of the fuel system ﬁlter is important.

uel tanks use supply pipes that allow water

uel directly from the bottom of the tank. If

Fuel Storage Tanks

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

Weekly

•

vice intervals

Ser

•

Reﬁll of the tank

•

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

nk.

Illustration 65

3. Remove the fuel priming pump (5).

4. Disconnect fuel line (3) and the connection (1).

Cap the fuel line with a suitable cap.

5. Remove the two nuts (4).

g01280509

Page 64

64 SEBU8191-01 Maintenance Section Governor Actuator - Check

6. Remove the fuel

7. Remove the joint from the lift pump (2). Discard

the joint.

lift pump (2).

Installation of the Lift Pump

1. Install a new joint to the lift pump (2).

2. Align the dr

pump.

Note: Ensur lift pump is installed.

3. Install th 25 N·m (18 lb ft).

4. Remove the the fuel line and the connection (1). Tighten the fuel line and the connection to a torque of 50 N·m (37 lb ft)

5. Fit the fuel priming pump (5) to the lift pump (2).

6. Restore the fuel supply to the lift pump.

ive for the lift pump (2). Install the lift

e that the oil seal is not damaged as the

enuts(4).Tightenthenutstoatorqueof

cap from the fuel line (3). Connect

If you inspect t the proper inspection procedure in order to avoid a ﬂuid penetration hazard. Refer to Operation and Maintenance M

Inspect all hoses for leaks that are caused by the following co

Cracking

•

Softness

•

Loose clamp

•

Replace hoses that are cracked or soft. Tighten any loose clam

Check for the following conditions:

End ﬁttings that are damaged or leaking

•

Outer cov

•

Exposedwirethatisusedforreinforcement

•

Outer covering that is ballooning locally

•

he engine in operation, always use

anual, “General hazard Information”.

nditions:

ps.

ering that is chafed or cut

7. Remove t Operation and Maintenance Manual, “Fuel System

- Prime”.

he air from the fuel system. Refer to

i02471

Governor Actu ator - Check

er for the governor to operate correctly, the

In ord control box must be calibrated to the actuator. The feedback parameters from the control box must

spond to the 0% and the 100% positions on the

corre actuator. Carry out a periodic calibration check of the governor system. Refer to Special Instruction,

doras Digital Governor” for more information.

“Pan

i02349879

Hoses and Clamps Inspect/Replace

680

e part of the hose that is kinked or crushed

Flexibl

•

Armoring that is embedded in the outer covering

•

A constant torque hose clamp can be used in place of any standard hose clamp. Ensure that the constant torque clamp.

Due to harden. Hardening of the hoses will cause hose clamps to loosen. This can result in leaks. A constant torqu clamps.

Each differences depend on the following factors:

•

hose clamp is the same size as the standard

extreme temperature changes, the hose will

e hose clamp will help to prevent loose hose

installation application can be different. The

of hose

Type

Type of ﬁtting material

Anticipated expansion and contraction of the hose

icipated expansion and contraction of the

Ant ﬁttings

ontact with high pressure fuel may cause ﬂuid

C penetration and burn hazards. High pressure fuel spray may cause a ﬁre hazard. Failure to fol-

ow these inspection, maintenance and service in-

l structions may cause personal injury or death.

Replace the Hoses and the Clam ps

fer to the OEM information for further information

Re on removing and replacing fuel hoses (if equipped).

Page 65

SEBU8191-01 65

Maintenance Section

Overhaul (Major)

The coolant sys system are not usually supplied by Perkins. The following text describes a typical method of replacing coolant hoses further information on the coolant system and the hoses for the coolant system.

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

1. Stop the engine. Allow the engine to cool.

2. Loosen th

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. Discon

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

For the correct coolant, see this Operation and

Note:

Maintenance Manual, “Fluid Recommendations”.

8. Reﬁl

9. Clean the cooling system ﬁller cap. Inspect the

10. Sta

l the cooling system. Refer to the OEM information for further information on reﬁlling the cooling system.

cooling system ﬁller cap's seals. Replace the

ling system ﬁller cap if the seals are damaged.

coo Install the cooling system ﬁller cap.

rt the engine. Inspect the cooling system for

leaks.

tem and the hoses for the coolant

. Refer to the OEM information for

d System: Hot coolant can cause seri-

are cool. Loosen the cooling system

e cooling system ﬁller cap slowly in

nect the old hose.

i02461950

Overhaul (Major)

Scheduling a Major Overhaul

The need for a several factors:

An increase

•

An increase of crankcase blowby

•

A decrease and variation of cylinder compression

•

Other fact a major overhaul:

The servi

•

The wear metal analysis of the lube oil

•

An increase in the levels of noise and vibration

•

An incre that the bearings and the surfaces that wear may need to be serviced. An increase in the levels of noise an require service.

Note: I decrease of wear metals in the lube oil. The cylinder liners may be worn so that polishing of the bore occur the wear metals.

Monit service hours. Consult Perkins Engines Stafford about scheduling a major overhaul.

Note: Thedrivenequipmentmayalsorequireservice when the engine is overhauled. Refer to the literature that

Majo

During a major overhaul, all of the bearings, sea disassembled. The parts should be cleaned. The parts should then be inspected. If necessary, the par inspected and measured for wear. The crankshaft may require regrinding. Alternatively, the crankshaft ma

ase of wear metals in the lube oil indicates

d vibration indicates that rotating parts

t is possible for oil analysis to indicate a

s. Also, the increased use of lube oil will dilute

or the engine as the engine accumulates

is provided by the OEM of the driven equipment.

r Overhaul Information

ls, joints, and components that wear should be

ts should be replaced. The crankshaft should be

ybereplaced.

major overhaul is determined by

of oil consumption

ors must also be considered for determining

ce hours of the engine

Inspecting Components

Inspect the following components during a major overhaul.

Page 66

66 SEBU8191-01 Maintenance Section Overhaul (Top End)

Engine mounted

•

Camshafts

•

Camshaft followers

•

Connecting r

•

Crankshaft and bearings

•

Gear train

•

Inlet air pi

•

Oil cooler

•

Pistons and rings

•

Cylinder l

•

Replace the crankshaft vibration damper.

ping

iners

aftercoolers

ods and bearings

i04328053

Overhaul (Top End)

Schedu

Top end overhauls should be scheduled according to the rec provides an accurate indication of the rate of valve wear. This measurement can be used to predict when a cyli

Note: Generally, cylinder heads wear out at different

s. In some cases, servicing the cylinder heads at

rate different times may be the most economic decision. This depends on the valve stem projection of the

vidual cylinders. However, this decision must

indi include the costs of additional downtime that is caused by this procedure. Perform an economic

ysis in order to determine if cylinder heads should

anal be serviced as a group or divided into smaller groups.

Top End Overhaul I nformation

p end overhaul involves servicing the cylinder

Ato heads. During a top end overhaul, one piston should be removed. Inspect the piston, piston rings, and the

linder liner. The condition of these components will

cy determine the period of the major overhaul. Refer to Service Manual for more information.

ling a Top End Overhaul

ession of the valve stems. This measurement

nder head requires replacement.

1. Remove the rock

2. Refer to Systems Operation, Testing and

Adjusting, “V

3. On all engine cylinders, record the clearance before any ad

4. Set the valve bridges.

5. Adjust the valve lash to 0.4 mm (0.016 inch).

The recorde excessive valve seat wear on individual valves. The recorded values can be used to schedule a top end overhaul.

An example of recorded valve lash

Table 23

Hours Inlet Exhaust Inlet Exhaust

500 0.4mm 0.4mm 0 0

1000 0.4 0.4 0 0

1500 0.35 0.35 0.05 0.05

2000 0.35 0.35 0.1 0.1

2500 0.3 0.3 0.2 0.2

3000 0.25 0.3 0.35 0.3

3500 0.25 0.35 0.5 0.35

4000 0.25 0.3 0.65 0.45

After 4000 hours running, the valve seat wear on the inlet is 0.65 mm (0.026 inch) and the exhaust is

mm (0.018 inch).

0.45

Note: Maximum permitted valve seat wear is

0 mm (0.040 inch).

1.0

In this example, the valves are still serviceable after

0 hours running.

400

When the valves approach the maximum wear limit,

e rockers can be removed and a measurement

th fromthecylinderheadfacetothetopofthevalve stems can be taken. When a new valve is installed

e protrusion of the valve stem would be 29.75 mm

th (1.171 inch). therefore, a maximum wear limit would be 30.75 mm (1.211 inch).

d values can be used to identify any

Recorded clearances on A1 cylinder

er covers.

alve Lash - Adjust”.

justments are made.

Tot a l v al

ve wear

Monitoring Valve Seat Wear

very 500 service hours record the valve lash. The

E monitoring of the valve seat wear should be carried out before any adjustment of the valve lash.

Page 67

SEBU8191-01 67

Maintenance Section

Radiator - Clean

i02415302

Radiator - Clean

Note: Adjust t

the effects of the operating environment.

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

Personal i

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

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

Pressur loose debris. Direct the air in the opposite direction to the fan's air ﬂow. Hold the nozzle approximately 6mm(0.2 move the air nozzle in a direction that is parallel with the radiator tube assembly. This will remove debris

between the tubes.

that is

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

ides.

both s

Use a degreaser and steam for removal of oil and

se. Clean both sides of the core. Wash the core

grea with detergent and hot water. Thoroughly rinse the core with clean water.

After cleaning the radiator, start the engine. Run the engine. This will help in the removal of debris and

drying of the core. Stop the engine. Use a light

the 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:

lds, mounting brackets, air lines, connections,

We clamps, and seals. Make repairs, if necessary.

he frequency of cleaning according to

adiator for these items: Damaged ﬁns,

njury can result from air pressure.

re. When using pressure air, wear a pro-

ir pressure a t the nozzle must be less

ized air is the preferred method for removing

5 inch) away from the radiator ﬁns. Slowly

imum water pressure for cleaning purposes

i02335775

Severe Service Application Check

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

Performanc

•

and fuel consumption

Fuel quali

•

Operational Altitude

•

Maintenance intervals

•

Oil selec

•

Coolant type and maintenance

•

Environmental qualities

•

Install

•

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 determ parameters.

Sever wear. Engines that operate under severe conditions may need more frequent maintenance intervals in order full service life.

Due t to identify all of the factors which can contribute to severe service operation. Consult your Perkins

er or your Perkins distributor for the unique

deal maintenance that is necessary for the engine.

operating environment, incorrect operating

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

lication.

app

kins maintains standards for the following

e such as power range, speed range,

tion and maintenance

ation

ine if the engine is operating within the deﬁned

e service operation can accelerate component

to ensure maximum reliability and retention of

o individual applications, it is not possible

Page 68

68 SEBU8191-01 Maintenance Section Speed Sensor - Clean/Inspect

Environmental Factors

Ambient tempe

exposed to extended operation in extremely cold environments or hot environments. Valve components ca the engine is frequently started and stopped in very cold temperatures. Extremely hot intake air reduces engine perfo

Quality of the air – The engine may be exposed to extended dirty or dusty, unless the equipment is cleaned regularly. Mud, dirt and dust can encase components. Maintenanc contain corrosive chemicals.

Buildup – C chemicals and salt can damage some components.

Altitude

operated at altitudes that are higher than the intended settings for that application. Necessary adjustments should be

– Problems can arise when the engine is

Incorre

ratures – The engine may be

n be damaged by carbon buildup if

rmance.

operation in an environment that is

e can be very difﬁcult. The buildup can

ompounds, elements, corrosive

made.

ct Operating Procedures

Table 24

Required Tools

Too l

A SE253 Crankshaft Turning Tool 1

Part

Number

Part Name Qty

Engine Speed Sensor

The crankshaft position sensor is located in the right hand side of the ﬂywheel housing.

1. Isolate the electrical supply to the engine.

Extended operation at low idle

•

Frequent hot shutdowns

•

Operat

•

Operating at excessive speeds

•

Operating outside the intended application

•

ing at excessive loads

Incorrect Maintenance Procedures

ding the maintenance intervals

Exten

•

Failure to use recommended fuel, lubricants and

•

ant/antifreeze

cool

i02461940

Spee

d Sensor - Clean/Inspect (Engine Sp eed Sensor and Overspeed Sensor)

en the engine is cranked, small metal particles

Wh are produced. These particles will contaminate the magnetic end of the crankshaft position sensor and

e overspeed sensor. Contamination will distort

th the signals that are produced by the sensors. The sensors should be regularly cleaned and adjusted in

rder to ensure a good signal.

Illustration 66

Typical exa mple

2. Remove the connection (3). Loosen the locknut (1).

3. Remove the sensor (2).

4. Use a soft, dry cloth in order to clean any debris

from the sensor (2).

Note: Do not use a wire brush in order to clean the sensor. Do not use abrasive material in order to clean the sensor.

5. Install Tooling (A). Use Tooling (A) in order to rotate the engine. Rotate the engine in order to align a tooth on the ring gear with the center of the tapped hole.

6. By hand, carefully install the sensor (2) until light contact is made with the ring gear.

Note: Do not tighten the sensor.

g01237852

Page 69

SEBU8191-01 69

Maintenance Section

Starting Motor - Inspect

Illustration 67

g01237854

7. Unscrew the sensor (2) by one complete turn in order to obtain a clearance (X) of 1 mm (0.04 inch).

8. Tighten the locknut (1). Do not allow the sensor (2) to rotate. Connect the connection (3).

9. Remove Tooling (A).

10. Restore the electrical supply to the engine.

4. Use a soft, dry c

loth in order to clean any debris

from the sensor (2).

Note: Do not us

eawirebrushinordertocleanthe sensor. Do not use abrasive material in order to clean the sensor.

5. Install Tooling (A). Use Tooling (A) in order to

rotate the engine. Rotate the engine in order to align a toot

h on the ring gear with the center of

the tapped hole.

6. By hand, car

efully install the sensor (2) until light

contact is made with the ring gear.

Note: Do no

t tighten the sensor.

Overspeed Sensor

The overspeed sensor is located in the left hand side of the ﬂywheel housing.

1. Isolate the electrical supply to the engine.

Illustration 69

g01237854

7. Unscrew the sensor (2) by one complete turn in

order to obtain a clearance (X) of 0.5 to 0.8 mm (0.02to0.03inch).

8. Tighten the locknut (1). Do not allow the sensor

(2) to rotate. Connect the connection (3).

9. Remove Tooling (A).

10. Restore the electrical supply to the engine.

i02462035

rting Motor - Inspect

Sta

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

arting motors is recommended.

Illustration 68

Typical example

g01237853

2. Remove the connection (3). Loosen the locknut (1).

3. Remove the sensor (2).

Note: Problems with the electric starting motor can

e caused by the following conditions: malfunction of

b the solenoid and malfunction of the electric starting system.

Inspect the electrical system for the following conditions:

Page 70

70 SEBU8191-01 Maintenance Section Turbocharger - Inspect

Loose connecti

•

Corrosion

•

Wires that are worn or frayed

•

Cleanliness

•

Make repairs, if necessary.

The starting motor pinion and the ﬂywheel ring gear must be in good condition in order for the engine to start pro starting motor pinion does not engage the ﬂywheel ring gear. The teeth of the starting motor pinion and the ﬂywhee irregular engagement.

Inspect th Listen for grinding when the engine is started. Inspect the teeth of the starting motor pinions and the ﬂywheel r teeth. Look for teeth that are broken or chipped. If damaged teeth are found, the starting motor pinions and the ﬂy

Refer to the Operation Manual TSL4165 for informa installing the starting motors.

e starting motors for proper operation.

ing gear. Look for patterns of wear on the

wheel ring gear must be replaced.

tion on removing the starti ng motors and

ons

perly. The engine will not start if the

l ring gear can be damaged because of

NOTICE Turbocharger tities of oil to enter the air inlet and exhaust systems. Loss of engine lubricant can result in serious engine damage.

Minor leakage of a turbocharger housing under extended low id as long as a turbocharger bearing failure has not occurred.

When a turbocharger bearing failure is accompanied by a signiﬁcant engine performance loss (exhaust smoke or eng engine operation until the turbocharger is repaired or replaced.

An inspection of the turbochargers can minimize unscheduled downtime. Also, the chance for potential damage to other engine parts is reduced.

Note: Turbocharger components require clearances that are precise. The turbocharger cartridge must be balanced due to high rpm.

The following conditions can cause a turbocharger to be out-of-balance:

bearing failures can cause large quan-

le operation should not cause problems

ine rpm up at no load), do not continue

i04328054

Turbocharger - Inspect

Periodic inspection and cleaning is recommended for the turbochargers. Fouling of the turbine wheels can contribute to loss of engine power and overall loss of engine efﬁciency.

If a turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to a turbocharger compressor wheel could allow parts from the compressor wheel to enter an engine cylinder. This can cause additional damage to the pistons, the valves, and the cylinder head.

The buildup of deposits

•

Chipping and/or ﬂaking of deposits

•

If the turbocharger must be removed for inspection, use caution. Do not break deposits from the turbine wheel. Do not attempt to clean the turbine wheel. For options regarding removal, installation, repair and replacement, refer to the Service Manual, or consult a Perkins distributor.

1. Remove the exhaust outlet piping and remove

the air inlet piping from the turbocharger. Visually inspect the piping for the presence of oil.

2. Turn the compressor wheel and the turbine wheel

by hand. The assembly should turn freely. Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing. There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing. If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing, the turbocharger should be reconditioned.

3. Check the compressor wheel for cleanliness.

If only the inlet side of the wheel is dirty, dirt and/or moisture is passing through the air ﬁltering system. If oil is found only on the back side of the wheel, there is a possibility of a failed turbocharger oil seal.

Page 71

SEBU8191-01 71

Maintenance Section

Walk-Around Inspection

Thepresenceof engine operation at no load. The presence of oil may also result from restriction of the inlet air (plugged air ﬁ the seal for the turbocharger compressor.

Note: Deposi on the turbine wheel. Turbine wheel will become unbalanced when the deposits ﬂake off. The turbocharg turbine wheel becomes unbalanced. However, remove deposits from the housing. Removing deposits fr blades of the new turbine wheel.

4. Inspect th deposits of ash and silicone. If deposits of 1.6 mm (0.06 inch) thickness are found or if the turbine is in conta must be disassembled and cleaned. Removal of the deposits can be difﬁcult.

5. Inspect the bore of the turbine housing for corrosion and deposits.

6. Clean the turbocharger compressor housing with standard shop solvents and a soft bristle brush.

er cartridge must be replaced when the

om the housing will prevent wear on the

e turbine wheel and the housing for

oil may be the result of extended

lters). This causes oil to leak past

ts of ash and silicone can accumulate

ct with the housing, the turbocharger

NOTICE For any type of ﬂuid. If leaking is observed, ﬁnd the source and correct the leak. If leaking is suspected, check the ﬂuid levels more often tha or ﬁxed, or until the suspicion of a leak is proved to be unwarranted.

Accumulated grease and/or oil on an engine is a ﬁre hazard. Remove the accumulated grease and oil. Refer to Operation and Maintenance Manual, “Engine Clean” for more information.

Ensure that the cooling system hoses are correctly

•

clamped and that the cooling system hoses 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 the 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.

leak (coolant, lube, or fuel) clean up the

n recommended until the leak is found

NOTICE

7. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing.

i02415322

Walk-Around Inspection

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

For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections and trash buildup. Make repairs, as needed:

The guards must be in the correct place. Repair

•

damaged guards or replace missing guards.

Wipe all caps and plugs before the engine is

•

serviced in order to reduce the chance of system contamination.

Excessive coolant leakage may indicate the need to replace a water pump. Refer to Operation and Maintenance Manual, “Water Pump - Inspect” for more information. If necessary, consult your Perkins dealer or your Perkins distributor.

Inspect the lubrication system for leaks at the front

•

crankshaft seal, the rear crankshaft seal, the oil pan, the oil ﬁlters and the rocker cover.

Inspect the piping for the air intake system and the

•

elbows for cracks and for loose clamps. Ensure that hoses and tubes are not contacting other hoses, tubes, wiring harnesses, etc.

Ensure that the areas around the rotating parts are

•

clear.

Inspect the alternator belt and fan drive belts for

•

cracks, breaks or other damage.

Inspect the wiring harness for damage.

•

Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt could cause the belt to break.

Page 72

72 SEBU8191-01 Maintenance Section Water Pump - Inspect

i04326852

Water Pump - Inspect

A failed water overheating problems that could result in the following conditions:

Cracks in the cylinder head

•

Apistonsei

•

Other potential damage to the engine

•

Note: The water pump seal is lubricated by the coolant in the cooling system. A normal condition is that a smal cools down and parts contract.

Visually pumps are not serviceable items. Replace a leaking water pump. Refer to Disassembly and Assembly for more i

pump may cause severe engine

zure

l amount of leakage to occur as the engine

inspect the water pumps for leaks. The water

nformation.

Page 73

SEBU8191-01 73

Warranty Section

Warranty Information

Warranty Section

Warranty Information

i01903596

Emissions Warranty Informatio

This engine may be certiﬁed to comply with exhaust emission standards and gaseous emission standards that are pr manufacture, and this engine may be covered by an Emissions Warranty. Consult your authorized Perkins dealer or to determine if your engine is emissions certiﬁed and if your engine is subject to an Emissions Warranty.

escribed by the law at the time of

your authorized Perkins distributor in order

Page 74

74 SEBU8191-01 Index Section

Index

Actuator Con

After Stopping Engine............................................ 26

Aftercooler Core - Clean/Test ................................ 41

Aftercoole

Alternator - Inspe ct ................................................ 42

Alternator Pulley - Check....................................... 42

Battery - Replace ................................................... 43

Battery Electrolyte Level - Check .......................... 43

Battery or

Before Starting Engine .................................... 10, 23

Belts - Inspect/Adjust/Replace (Alternator Belt) .... 46

Adjustme

Inspection........................................................... 46

Replacement...................................................... 46

Belts - I

Adjustment ......................................................... 45

Inspection........................................................... 44

Replace

Burn Prevention....................................................... 7

Batteries............................................................... 7

Coolan

Oils....................................................................... 7

Cold W

Cooling System Coolant - Change (Inhibitor) ........ 49

Drain .................................................................. 50

Fill ...................................................................... 5

Flush .................................................................. 51

Cooling System Coolant (ELC) - Change.............. 47

Drai

Fill ...................................................................... 49

Flush .................................................................. 48

ing System Coolant Level - Check ................. 52

Cool

Crushing Prevention and Cutting Prevention .......... 9

ven Equipment - Check..................................... 52

Dri

Electrical System .................................................... 11

ergency Stopping ............................................. 26

Emissions Warranty Information............................ 73

Engine - Clean....................................................... 53

ngine Air Cleaner Element - Replace.................. 53

trol Linkage - Lubricate ..................... 41

r Core - Inspect...................................... 42

Battery Cable - Disconnect ................... 44

nt ......................................................... 46

nspect/Adjust/Replace (Fan Drive Belts)... 44

ment...................................................... 45

t................................................................. 7

eather Starting ........................................... 24

n .................................................................. 47

Engine Air Cleaner Service Indicator - Inspect ...... 54

Service Indicator Check ..................................... 54

Service Indi

Engine Crankcase Breather - Clean...................... 54

Engine Description ................................................ 15

Engine Cool

Engine Speciﬁcations......................................... 15

Engine Electronics .................................................. 11

System Desc

Engine Lifting......................................................... 19

Engine Mounts - Inspect........................................ 55

Engine Oil

Drain the Engine Lubricating Oil ........................ 58

Fill the Oil Pan.................................................... 58

Replace th

Engine Oil Filter (Auxiliary) - Change .................... 55

Change the Filter with the Engine in Operation.. 55 Engine Oi

Engine Oil Pump - Inspect..................................... 56

Engine Oil Sample - Obtain ................................... 57

Initiat

Obtain the Sample and the Analysis.................. 57

Engine Operation................................................... 25

Engine P

Visual Inspection................................................ 59

Engine Starting ................................................ 10, 23

Engine

Engine Storage...................................................... 19

Level “A ” ........................................................... 19

Level “

Level “C ” .......................................................... 19

Engine Valve Lash - Inspect/Adjust (Valves and Valve

es) ............................................................... 59

Bridg

Fan Drive Pulley - Check....................................... 59

ures and Controls ........................................... 20

Feat

Fire Prevention and Explosion Prevention .............. 7

Fire Extinguisher .................................................. 9

s, Tubes and Hoses ...................................... 9

Line

Fluid Recommendations........................................ 27

Cooling System Speciﬁcations........................... 35

ELC

Engine Oil .......................................................... 28

Fuel Speciﬁcations............................................. 31

eral Lubricant Inform ation ........................... 27

Gen

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

California Proposition 65 Warning ....................... 4

tera

Maintenance ........................................................ 4

Maintenance Intervals.......................................... 4

eration ............................................................. 4

Overhaul .............................................................. 4

Safety................................................................... 4

uel Conservation Pra ctices.................................. 25

Fuel Injector - Inspect/Adjust ................................. 60

cator Reset...................................... 54

ing and Lubrication ......................... 16

ription ............................................. 11

and Filter - Change .............................. 57

e Oil Filter ......................................... 58

l Level - Check ....................................... 56

ing an Oil analysis Program ...................... 57

rotective Devices - Check ....................... 59

Stopping .............................................. 10, 26

B ” ........................................................... 19

Cooling System Maintenance .................... 37

ture Information.................................

.......... 4

Page 75

SEBU8191-01 75

Index Section

Fuel System - Pr

Fuel System Filter - Replace ................................. 61

Fuel Filter with Water Separator ........................ 61

Fuel System Pr

Drain .................................................................... 62

Fuel Tank Water and Sediment - Drain ................. 62

Drain the Wat

Fuel Storage Tanks............................................ 63

Fuel Tank ........................................................... 63

Fuel Transf

Replacement of the Lift Pump............................ 63

General Ha

Containing Fluid Spillage ..................................... 6

Fluid Penetration.................................................. 6

Pressure A

General Information ............................................... 12

Governor Actuator - Check.................................... 64

Hoses and Clamps - Inspect/Replace ................... 64

Replace the Hoses and the Clamps .................. 64

Important Safety Information ................................... 2

ng and Storage ................................................ 19

Lifti

Maintenance Interval Schedule ............................. 40

tenance Section ............................................. 27

Main

Model View Illustrations......................................... 13

4012-46A ........................................................... 13

l Views .......................................................... 13

Mode

Monitoring System................................................. 20

Mounting and Dismounting...................................... 9

ime .............................................. 60

imary Filter/Water Separator -

er and the Sediment..................... 63

er Pump (Lift Pump) - Inspect ............. 63

zard Information .................................... 5

ir and Water........................................ 6

Plate Locations and Film Locations....................... 17

Engine Identi

Serial Number Plate ........................................... 18

Product Identiﬁcation Information .......................... 17

Product Info

Radiator - Clean .................................................... 67

Reﬁll Capac

Cooling System.................................................. 27

Fuel System ....................................................... 27

Lubricati

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

(1) Unive

(2) Hot Coolant..................................................... 5

Safety Section ......................................................... 5

Sensors a

Boost Pressure Sensors .................................... 21

Coolant Temperature Switches .......................... 21

Engine O

Overspeed Sensor ............................................. 22

Sensor Locations ............................................... 20

Speed Se

Severe Service Application - Check ...................... 67

Environmental Factors ....................................... 68

ect Maintenance Procedures .................... 68

Incorr

Incorrect Operating Procedures......................... 68

Speed Sensor - Clean/Inspect (Engine Speed Sensor

and Ov

Start

Starting the Engine ................................................ 23

Stop

Table of Contents..................................................... 3

Tur

erspeed Sensor)....................................... 68

Engine Speed Sensor ........................................ 68

Overspeed Sensor ............................................. 69

ing Motor - Inspect ......................................... 69

Normal Engine Starting Procedure .................... 23

ping the Engine .............................................. 26

bocharger - Inspect .......................................... 70

ﬁcation........................................... 17

rmation Section .................................. 12

ities..................................................... 27

on System ............................................ 27

rsal Warning .......................................... 5

nd Electrical Components ..................... 20

il Pressure Switch ............................... 22

nsor .................................................... 21

Operation Section.................................................. 19

Overhaul (Major).................................................... 65

jor Overhaul Information ............................... 65

Scheduling a Major Overhaul............................. 65

Overhaul (Top End) ............................................... 66

heduling a Top End Overhaul ........................ 66

Top End Overhaul Information ........................... 66

Walk-Around Inspection ........................................ 71

rranty Information ............................................. 73

Warranty Section ................................................... 73

Water Pump - Inspect ............................................ 72

lding on Engines with Electronic Controls ........ 12

Page 76

76 SEBU8191-01 Index Section

Page 77

Product and Dealer Information

Note: For product identiﬁcation plate locations, see the section “Product Identiﬁcation Information” in the Operation

and Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identiﬁcation Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:

Page 78