Perkins Engine 4016-61 TRG Service Manual

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Page 1

Operation and Maintenance Manual

SEBU8604

March 2010

4016-61 TRG Industrial Engine

(Engine)

S16

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

SEBU8604 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 ..................................................................... 77

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 .......................................... 22

Engine Starting ..................................................... 26

Engine Operation .................................................. 28

Engine Stopping ................................................... 29

Maintenance Section

Reﬁll Capacities .................................................... 30

Maintenance Interval Schedule ............................ 42

Warranty Section

Warranty Information ............................................ 76

Page 4

4 SEBU8604 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

SEBU8604 5

Safety Section

Safety Messages

Safety Section

i03835895

Safety Me ssage 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 SEBU8604 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 ﬂ uid 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

SEBU8604 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 ca use 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 and 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 SEBU8604 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

SEBU8604 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 SEBU8604 Safety Section Before Starting Engine

i02813489

Before Start ing 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. To 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 Stopping

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

SEBU8604 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 Electron ics

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 SEBU8604 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 m inimum 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 sw itch in the open position (5) Disconnected battery cables (6) Battery (7) Electrical/Electronic component (8) Maximum distance between the component that is being

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

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

SEBU8604 13

Product Information Section

Model Views

i03754000

Model View Illustrations

4016-61TRG

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 SEBU8604 Product Information Section Model Views

Illustration 1 0

Left side view of engine

(1) Engine crankcase brea ther ( A Bank) (2) Thermostat housing (A Bank) (3) Electronic governor actuator (4) Thermostat housing (B Bank)

(5) Engine crankcase breather (B Bank) (6) Air shutoff valve (B Bank) (7) 3x Oil ﬁ lters (B B ank) (8) Oil cooler

g02029553

(9) Oil level gauge (Dipstick) (10) Oil ﬁller (11) Water pump (12) Stop solenoid

Page 15

SEBU8604 15

Product Information Section

Model Views

Illustration 11

Right side view of engine

(13) Air cleaner (14) Restriction indicator for air cleaner (15) Turbocharger (16) Electronic governor control unit (17) Alternator

(18) Fuel ﬁlters (19) Oil drain plug (20) Fuel priming pump (21) Oil cooler (A B ank) (22) 3x Oil ﬁlters (A Bank)

i03754029

Engine Description

The 4016-61 TRG engine model is designed for power generation. The engine is available with turbocharged aftercooled aspiration.

g02029554

(23) Starter relay (24) Starting m otor (25) Aftercooler

Engine Speciﬁcations

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

front of the engine is farthest from the ﬂywheel.

nk A cylinders are on the right hand side of the

Ba engine. Bank B cylinders are on the left hand side of the engine. To determine the left and right sides of

he engine, stand behind the ﬂywheel and face the

t dampers.

Page 16

16 SEBU8604 Product Information Section Model Views

Illustration 12

4016-61 TRG engine model

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

Table 1

4016-61 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

61.123 L (3729.954 in

Counterclockwise

1A-1B-3A-3B-7A-7B-5A-5B-8A-8B-

6A-6B-2A-2B-4A-4B

0.40 mm (0.016 inch)

(7.480 inch)

13:1

g01210841

)

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

SEBU8604 17

Product Information Section

Product Identiﬁcation Information

i03754088

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 R**** U00001M.

_________________________________________ 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

Type of engine (Diesel)

F TG

S TEG3

W TRG2

X TGR3

G 4016-E61-TRS

TAG

TAG1

TAG2

TAG3

TWG

TWG2

TWG3

TRG1

TEG2

Type of engine (Gas)

Gas unit

TESI

TESI Combined Heat and Power unit

TRS Combined Heat and Power Unit

TRS Gas Unit

00001

Table 2

____________________________________Engine Number

____________________________________ Year of Manufacture

Application

G Genset

Gas

Table 4

Number of Cylinders

F 6

H 8

M 12

R 16

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 SEBU8604 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

Typical example

The serial number plate (1) on a engine is located on the left side of the cylinder block (bank B).

g02029586

Page 19

SEBU8604 19

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i03880885

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.

lustration 15

Typical examp le

Use a hoist to remove heavy components. Use a lifting beam (A) to lift the engine. All supporting

embers (chains and cables) should be parallel

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

g02126835

Page 20

20 SEBU8604 Operation Section Lifting and Storage

Illustration 1 6

(1) Front lifting eyes (2) Rear lifting eye

ToremovetheengineONLY,usetheliftingeyesthat are shown in illustration 16. If necessary, remove engine components in order to avoid damage from the lifting device.

g02131153

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

Illustration 17

g02130795

Note: The lifting eye (3) must NOT b e used in order to lift the engine. The lifting eye (3) has

not been designed in order to lift the engine. The lifting eye is used in factory assembly of engine components.

Page 21

SEBU8604 21

Operation Section

Lifting and Storage

i03781209

Engine Storage

Refer to Perki ST16 3UB for information on engine storage.

There are thr Level “A, B and C”.

ns Engine Company Limited, Stafford,

ee different levels of engine storage.

Level “A ”

Level “A” wi engines and for gas engines. This level is used for engines that are transported in a container or by a truck.

ll give protection for 12 months for diesel

Level “B ”

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

ection under normal conditions of storage

Level “C ”

This level is additional to level “B”. Level “C” will give protection for ﬁve years in tropical or in arctic

es. Level “C” also meets MOD NES 724

climat Level “J” for Europe, when engines are stored in an unheated building or in the open under a waterproof cover.

Page 22

22 SEBU8604 Operation Section Features and Controls

Features and Controls

i03882309

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 Sensors

•

Engine speed (Sensor)

•

Engine overspeed (Sensor or Switch)

•

Sensors and Electrical Components

Sensor Locations

i03781211

Illustration 1 8

(1) Electronic control unit (ECU) (2) Coolant tempe rature sensor (3) Boost pressure sensor (4) Oil pressure switch

(5) High turbine inlet temperature shutdown

sensor (A bank) (6) Thermocouple (7) Speed sensor

g02088773

(8) Overspeed sensor (9) High turbine inlet te mperature shutdown

sensor (B bank)

(10) Oil pressure switch

Page 23

SEBU8604 23

Operation Section

Features and Controls

The Illustrati

ons show the typical locations of the sensors on the engine. Speciﬁc engines may appear different from the illustrations due to differences in applications

Coolant Tempe

rature Sensor

The boost press

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

Illustration 19

Coolant temperature switches

g02088775

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

Boost Pressure Sensors

llustration 20

Boost pressure sensor

g02125658

Page 24

24 SEBU8604 Operation Section Features and Controls

Engine Oil Pressure Switch

Illustration 2 1

Engine oil pressure sensor

(4) Oil pressure sensor (A Bank) (9) Oil pressure sensor (B Bank)

An oil pressure sensor is installed on both side of the engine. The engine oil pressure sensors are mounted in the main oil gallery. The engine oil pressure sensors are supplied for connecting to an OEM supplied panel.

High Turbine Inlet Temperature Shutdown Sensor

g02041294

Illustration 2 2

(5) High turbine inlet temperature shutdown

sensor (A bank)

(8) High turbine inlet temperature shutdown

sensor (B bank)

02124274

Page 25

SEBU8604 25

Operation Section

Features and Controls

Illustration 23

Thermocouple

g02123434

Four thermocouples are installed. One thermocouple is installed in each of the exhaust manifolds. There are two high turbine inlet temperature shutdown sensors. One sensor monitors each engine bank. A sensor monitors two thermocouples. If high temperatures are indicated the engine will be shutdown.

The speed senso

r(7)shouldbeservicedat the required maintenance interval. Refer to the Operation and Maintenance Manual, “Speed Sensor, Clean/Inspec

t”.

Failure of the Speed Sensor

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 (7), the engine will shut down. A faulty speed sensor shou

ld be replaced.

Note: Intermittent failure of the speed sensor will cause the e

ngine to run erratically. This may also

cause overspeed.

Overspeed Sensor

Speed Sensor

Illustration 24

eed sensor

g02123433

Illustration 25

Overspeed sensor

g01231518

The signal from the overspeed sensor (8) is connected to the overspeed switch or the overspeed circuit in the OEM supplied panel.

The location of the sensor can vary depending on the application.

Page 26

26 SEBU8604 Operation Section Engine Starting

Engine Starting

i03873029

Before Start ing 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 valves and open the return lines (i

2. If the engine has not been started for several weeks, f system. Also, when fuel ﬁlters have been changed, some air pockets will be trapped in the engine. In thes to the Operation and Maintenance Manual, “Fuel System-Prime”formoreinformation.

ngine is started, perform the required

nance Manual, “Maintenance Interval

t start the engine or move any of the

ontrols.

f equipped).

uel may have drained from the fuel

e instances, prime the fuel system. Refer

a. Ensure that the

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

b. Turn the keyswitch to the START position.

Hold the keyswitch in this position until the oil press (14.5040 psi). Continue to hold the keyswitch in the START position for an additional 10 seconds.

Note: The keyswitch is part of the OEM supplied panel. The e Refer t o OEM supplied instructions for the correct starting procedure.

c. Turn the keyswitch to the STOP position.

d. Reconnect

The engine is now ready to run.

xact procedure for starting may vary.

governor stays in the STOP

ure gauge indicates 100 kPa

the speed pickup connector.

i02415221

Starting the Engine

Normal Engine Starting Procedure

Illustration 26

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.

g02114793

Note: When possible, ensure that the engine is not started under load.

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 27

SEBU8604 27

Operation Section

Engine Starting

i02415223

Cold Weath er 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 28

28 SEBU8604 Operation Section Engine Operation

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 P ractices

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 29

SEBU8604 29

Operation Section

Engine Stopping

i02415227

Stopping the Eng ine

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 30

30 SEBU8604 Maintenance Section Reﬁll Capacities

Maintenance Section

Reﬁll Capacities

i03754119

Reﬁll C apacities

Lubrication S ystem

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

Table 5

Engine

Reﬁll Capacities

Compartment or System 4016 TRG

Crankcase Oil Sump

(1)

These values are the total capa cities for the crankcase oil sump which includes the standard factory installed oil ﬁlters and oil coolers. Engines with auxiliary oil ﬁlters w ill require additional oil. Refer to the OEM speciﬁcations for the capacity of the auxiliary oil ﬁlter.

(1)

238 L (52.4 Imp gal)

Fuel System

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

Table 7

Engine

Reﬁll Capacities

Compartment or System 4016

Minimum Cap Tan k

Fluid Re c o

acity of Fuel

22500 L (4949 Imp gal)

mmendations

i03837413

(Cooling System Speciﬁcations)

General Coolant Information

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

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

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.

le 6

Tab

ine

Eng

Reﬁll capacities

Compartment or System Liters

Engine cooling system 95

Secondary cooling system

External System Per OEM

(1)

The volume of coolant that is given in this table is for the engine. The volume for the total cooling capacity w ill depend on the application.

(2)

Refer to the OEM speciﬁcations .

(1)

(2)

NOTICE

uently check the speciﬁc gravity of the coolant for

Freq proper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

Contamination of the cooling system

•

Overheating of the engine

•

Foaming of the coolant

•

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

Page 31

SEBU8604 31

Maintenance Section

Reﬁll Capacities

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

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

Coolant is n Water, additives, and glycol.

lures are related to the cooling

ged radiators or heat exchangers.

enance. Cooling system maintenance is

s the quality of the fuel and the lubricating

ormally composed of three elements:

Water

Water is used in the cooling system in order to transfer h

Distilled water or deionized w ater is recommen

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

If disti use water with the properties that are listed in T able 8.

Table 8

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

Local water utility company

•

Agricultural agent

•

eat.

ded for use in engine cooling systems.

: Hard water, softened water that has been

lled water or deionized water is not available,

Acceptable Water

Property Maximum Limit

Chloride (Cl) 40 mg/L

Sulfate (SO4) 100 mg/L

Total Hardness 170 mg/L

Tot a

lSolids

Acidity

pH of 5.5 to 9.0

340 m

g/L

Formation of mi

•

Rust

•

Scale

•

Foaming of th

•

Many additives are depleted during engine operation. These addit

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

Formation of gel compounds

•

Reduction

•

Leakage of the water pump seal

•

Plugging of radiators, coolers, and small passages

•

neral deposits

ecoolant

ives must be replaced periodically.

tration of additives can cause the

of heat transfer

Glycol

Glycol in the coolant helps to provide protection against

•

For optimum performance, Perkins recommends a 1:1 mi

Note: Use a mixture that will provide protection again

Note: 100 percent pure glycol will freeze at a temp

Most conventional coolants use ethylene glycol. Prop with water, ethylene and propylene glycol provide similar protection against freezing and boiling“. Refer to T

the following conditions:

Boiling

Freezing

tion of the water pump

Cavita

xture of a water/glycol solution.

st the lowest ambient temperature.

erature of −23 °C (−9°F).

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

ables 9 and 10.”.

Independent laboratory

•

Additives

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

Corrosion

•

Table 9

Concentration

50 Percent

60 Percent

Ethylene Glycol

Freeze

Protection

−36 °C (−33 °F) 106 °C (223 °F)

−51 °C (−60 °F) 111 °C (232 °F)

Boil

Protection

Page 32

32 SEBU8604 Maintenance Section Reﬁll Capacities

NOTICE

Do not use prop

ylene glycol in concentrations that exceed 50 percent glycol because of the reduced heat transfer capability of propylene glycol. Use ethylene glycol in cond

itions that require additional protection

against boiling or freezing.

Table 10

Propylene Glycol

Concentration

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

Freeze

Protection

Anti-Boil

Protection

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

Coolant Recommendations

The following two coolants are used in Perkins diesel engines:

Preferred – Perkins Extended Life Coolant (ELC)

Extended Life C

oolant (ELC)

Perkins provides Extended Life Coolant (ELC) for useinthefoll

Heavy-duty spark ignited gas engines

•

Heavy-duty diesel engines

•

Automotive

•

owing applications:

applications

The anti-corrosion package for ELC is different from the anti-co

rrosion package for other coolants. ELC is an ethylene glycol base coolant. However, ELC contains organic corrosion inhibitors and antifoam agents wit

h low amounts of nitrite. Perkins ELC has been formulated with the correct amount of these additives in order to provide superior corrosion protectio

n for all metals in engine cooling systems.

ELC is available in a 1:1 premixed cooling solution with dist

illed 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. T

he Premixed ELC is also recommended for

topping off the cooling system.

Acceptable – A commercial heavy-duty coolant that meets “ASTM D4985” speciﬁcations

NOTICE Do not use a commercial coolant/antifreeze that only meets the ASTM D3306 speciﬁcation. This type of

nt/antifreeze is made for light automotive appli-

coola cations.

Perkins recommends a 1:1 mixture of water and

ol. This mixture of water and glycol will provide

glyc optimum heavy-duty performance as a coolant.

e: A commercial heavy-duty coolant that

Not

meets “ASTM D4985” speciﬁcations MAY require a treatment with an SCA at the initial ﬁll. Read the label

he instructions that are provided by the OEM of

or t the product.

Table 11

Coolant Service Life

Coolant Type Service Life

Perkins ELC

Commercial Heavy-Duty

oolant that meets

“ASTM D4985”

Perkins POWERPART

Commercial SCA and

SCA

Water

6,000 Service Hours or

Three Years

3000 Service Hours or

Two Years

3000 Service Hours or

Two Years

3000 Service Hours or

Two Years

ELC Conc

entrate is also available. ELC Concentrate canbeusedtolowerthefreezingpointto−51 °C (−60 °F) for arctic conditions.

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

ELC Co

mbers.

oling System Maintenance

Correct additions to the Extended Life Coola

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

In the coolant and the additives, you must maintain the recommended concentration of Extended Life C lowers the proportion of additive. This will lower the ability of the coolant to protect the system from pitting,

rom cavitation, from erosion, and from deposits.

NOTICE

order to maintain the correct balance between

oolant (ELC). Lowering the proportion of coolant

Page 33

SEBU8604 33

Maintenance Section

Reﬁll Capacities

NOTICE Do not use a con system that is ﬁlled with Extended Life Coolant (ELC).

Do not use stan (SCA). Only use ELC Extender in cooling systems that are ﬁlled with ELC.

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

ventional coolant to top-off a cooling

dard supplemental coolant additive

NOTICE

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.

After the cooling system is drained and after the cooling system is reﬁlled, install the ﬁller cap. Operate the engine until the coolant level reaches the normal operating temperature. Shut the engine down using the normal shutdown procedure.

As needed, add the coolant mixture in order to ﬁll the system to the speciﬁed level. Install the ﬁller cap.

Changing to Perkins ELC

4. Use Perkins cle

the instruction on the label.

5. Drain the clea the cooling system with clean water.

6. Fill the cool operate the engine until the engine is warmed to 49° to 66°C (120° to 150°F).

Incorrect or incomplete ﬂushing of the cooling system can result in damage to copper and other metal components.

To avoid damage to the cooling system, make sure to completel Continue to ﬂush the system until all the signs of the cleaning agent are gone.

7. Shut down the engine by using the normal

Note: Th

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

8. Repeat

9. Fill t

y ﬂush the cooling system with clear water.

shutdown procedure. Drain the cooling system intoasu system w ith clean water.

the system is completely clean.

ELC.

itable container and ﬂush the cooling

e cooling system cleaner must be thoroughly

t. The cleaner may also corrode the cooling

the Steps 6 and repeat the steps 7 until

hecoolingsystemwiththePerkinsPremixed

aner to clean the system. Follow

ner into a suitable container. Flush

ingsystemwithcleanwaterand

NOTICE

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

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

Dispose of all ﬂuids according to local regulations and mandates.

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to local

regulations.

3. Flush the system with clean water in order to

remove any debris.

ELC C

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:

•

ooling System Contamination

NOTICE

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.

Page 34

34 SEBU8604 Maintenance Section Reﬁll Capacities

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 cont

Maintain the system as a conventional Heavy-Duty

•

Coolant. Tre

aminationtolessthan10percent.

atthesystemwithanSCA.Change the coolant at the interval that is recommended for the conventional Heavy-Duty Coolant.

Commercial Heavy-Duty Coolant and SCA

NOTICE Commercial Heavy-Duty Coolant which contains 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 regulat

ors 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

zing. Perkins recommends the use of a

or free refractometer for checking the glycol concentration.

ns engine cooling systems should be tested

Perki at 500 hour intervals for the concentration of Supplemental Coolant Additive (SCA).

Additions of SCA are based on the results of the test. An SCA that is liquid may be needed at 500 hour

rvals.

inte

Refer to Table 12 for part numbers and for quantities

of SC

Table 12

Perkins Liquid SCA

Part Number Quantity

21825735 10

Adding the SCA to Heavy-Duty C oolant at the Initial Fill

Use the equatio

nthatisinTable13todeterminethe amount of Perkins SCA that is required when the cooling system is initially ﬁlled.

Table 13

Equation For Adding The SCA To The Heavy-Duty

Coolant At The Initial Fill

V×0.045=X

V is the total volume of the cooling system.

X is the amount of SCA that is required.

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

Table 14

Example Of The Equation For Adding The SCA To

The Heavy-

Tot al Vo l ume

of the Cooling

System (V

15 L (4 US gal) × 0.045 0.7 L (24 oz)

Duty Coolant At The Initial Fill

Multiplication

Factor

)

Amount of SCA

that is Required

(X)

Adding The SCA to The Heavy-Duty Coolant For Maintenance

Heavy-duty 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 Table 15 to determine the amount of Perkins SCA that is required, if necessary:

Table 15

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.

Coolant For Maintenance

V×0.014=X

Commercial heavy-duty coolant that meets “ASTM D4985” speciﬁcations MAY require an addition of SCA at the initial ﬁll. Read the label or the instructions that are provided by the OEM of the product.

Table 16 is an example for using the equation that is in Table 15.

Page 35

SEBU8604 35

Maintenance Section

Reﬁll Capacities

Table 16

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant For Maintenance

Total Volume

of the Cooling

System (V)

15 L (4 US gal) × 0.014 0.2 L (7 oz)

Multiplication

Factor

Amount of SCA that is Required

(X)

Cleaning the System of Heavy-Duty Coolant

Perkins cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion. Perkins cooling system cleaners dissolve mineral scale, corrosion products, light oil contamination and sludge.

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.

i03837412

Fluid Recommendations (Fuel Speciﬁcations)

Fuel Recommendations

To get the correct power and performance from the engine, use a fuel of the correct quality. The recommended fuel speciﬁcation for Perkins engines is shown below:

Class A1 Fuels

Cetane number_________________________ ___________ ___50

•

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

•

Carbon residue__________________________________0.20%

•

Ramsbottom on 10% reidue

Sulfur content___________ 0.05% of mass, maximum

•

Distillation___________________56% at 350 °C (662 °F)

•

Lubricity_________________________ _____460 micrometers

•

maximum wear scar on “ISO 12156 - 1”

Class A2 Fuels

Viscosity____

•

Carbon residue__________________________________0.20%

•

Ramsbottom on

Sulfur content___________0.05% of mass, maximum

•

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

•

Lubricity_

•

maximum wear scar on “ISO 12156 - 1”

Cetane numb

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

Viscosity

This is th resistance is outside the limits, the engine and the engine starting performance in particular can be affected

Sulfur

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

Distillation

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

Lubr

This is the capability of the fuel to prevent pump wear.

Diesel engines have the ability to burn a variety of fuels. These fuels are divided into two general gro

•

“DERV to EN59 0”

ating oil change interval is reduced.

carbons can affect the characteristics of

icity

ups:

Group 1 (preferred fuels)

Group 2 (permissible fuels)

oup 1 (preferred fuels): Speciﬁcation

_______

_____________________________

low cetane number can be the root

eresistancetoﬂow of a ﬂuid. If this

gine wear. When only high sulfur fuels

1.5to5.5cStat40°C(104°F)

10% reidue

460 micrometers

Cetane number_________________________ ___________ ___45

•

Page 36

36 SEBU8604 Maintenance Section Reﬁll Capacities

Note: Only use A

rctic fuels when the temperature is below 0 °C (32 °F). Do not use Arctic fuels when the ambient temperature is above 0 °C (32 °F). To ensure thatthetimep

eriod between cranking the engine and ﬁrst ﬁre is kept to a minimum, only use fuel of the correct viscosity 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 lubricity.

Group 2 (permissible fuels): Speciﬁcation

These fuel

speciﬁcations are considered acceptable for issues of warranty. However,these fuels may reduce the life of the engine, the engine's maximum power and t

he engine's fuel efﬁciency.

“ASTM D975 - 91 Class 1D”

“JP7, Mil T38219”

“NATO F63

”

NOTICE These fuels should have a wear scar value of 650 micrometers maximum *HFRR to ISO 12156 - 1.*

Low tem

perature fuels

Special fuels for use in cold weather may be available

gine operation at temperatures below 0 °C

for en (32 °F). These fuels limit the formation of wax in the fuel oil at low temperatures. If wax forms in the fuel

his could stop the ﬂow of fuel oil through the ﬁlter.

oil, t

Note: These fuels that lack lubricity may cause the

owing problems:

foll

Low engine power

•

Refer to the fol

lowing 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 fuel

s that meet the speciﬁcations in Table 17 will help to provide maximum engine service life and performance. In North America, diesel fuel that is identiﬁ

ed as No. 2-D in “ASTM D975” generally meets the speciﬁcations. Table 17 is for diesel fuels that are distilled from crude oil. Diesel fuels from other sour

ces could exhibit detrimental properties

that are not deﬁned or controlled by this speciﬁcation.

Table 17

Perkins Speciﬁcations for Distillate Diesel Fuel

Speciﬁcations

Aromatics

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 engines)

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

ASTM Test

“D482”

“D524”

“D613”

(continued)

Difﬁcult starting in hot conditions or in cold

•

conditions

White smoke

•

erioration of emissions and misﬁre at certain

Det

•

operating conditions

ofuel: Speciﬁcation

Biofuel: A 5% mix of RME to EN14214 in conventional

el is permitted.

NOTICE

Water emulsion fuels: These fuels are not permitted

Page 37

SEBU8604 37

Maintenance Section

Reﬁll Capacities

(Table 17, 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 s ulfur fuels also increase the potential for c orrosion of internal components. Fuel sulfur levels above 0.5 percent ma y signiﬁcantly s horten the oil change interval. For additional information, see this publication, “Fluid Recommendations/Engine Oil” topic (M aintenance S ection).

(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 v iscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to bring down the viscosity t o a 20 cS t viscosity.

(3)

Follow the test conditions and pr ocedures 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 the “ASTM D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system.

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 18. However, the fuel that is selected must meet the requirements that are speciﬁed in Table 17. These fuels are intended to be used in operating temperatures that are down to −54 °C (−65 °F).

Table 18

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 Distillate Diesel Fuel” Table. Consult the supplier for the recommended additives in order to maintain the correct fuel lubricity.

These fuels are lighter than the No. 2 grades of fuel. The cetane number of the fuels in Table 18 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 17.

NOTICE

(1)

Page 38

38 SEBU8604 Maintenance Section Reﬁll Capacities

i03837410

Fluid Recommendations (General Lubr

icant

Information)

Engine Oil

Commercial Oils

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

Only use commercial oils that meet the following classiﬁc

API CG-4

•

API CH-4

•

In order oil, refer to the following explanations:

EMA DHD

Association (EMA) has developed lubricant recommendations as an alternative to the API oil classi Guideline that deﬁnes a level of oil performance for these types of diesel engines: high speed, four stroke cycle be used in Perkins engines when the following oils are recommended: API CH-4, API CG-4, and API CF-4. performance in comparison to API CG-4 and API CF-4.

DHD-1 oils will meet the needs of high performance Perkins diesel engines that are operating in many appl used to deﬁne DHD-1 are similar to the new API CH-4 classiﬁcation. Therefore, these oils will also mee low emissions. DHD-1 oils are designed to control the harmful effects of soot with improved wear resistance and These oils will also provide superior piston deposit control for engines with either two-piece steel pistons

aluminum pistons.

siﬁcations. These API classiﬁcations are

nditions.

ations:

to make the correct choice of a commercial

-1 – The Engine Manufacturers

ﬁcation system. DHD-1 is a Recommended

, heavy-duty, and light duty. DHD-1 oils may

DHD-1 oils are intended to provide superior

ications. The tests and the test limits that are

t the requirements for diesel engines that require

improved resistance to plugging of the oil ﬁlter.

All DHD-1 oils m with the base stock and w ith the viscosity grade of the ﬁnishedcommercialoil.Theuseof“APIBase Oil Interchan DHD-1 oils. This feature reduces the variation in performance that can occur when base stocks are changed in co

DHD-1 oils are recommended for use in extended oil change inte oil. These oil change interval programs are based on oil analysis. DHD-1 oils are recommended for conditions dealer or your Perkins distributor has the speciﬁc guidelines for optimizing oil change intervals.

API CH-4 – API CH-4 oils were developed in order to meet the requirements of the new high performance diesel eng meet the requirements of the low emissions diesel engines. API CH-4 oils are also acceptable for use in older d use high sulfur diesel fuel. API CH-4 oils may be used in Perkins engines that use API CG-4 and API CF-4 oils performance of API CG-4 oils in the following criteria: deposits on pistons, control of oil consumption, wear of pisto and corrosion.

Three ne CH-4 oil. The ﬁrst test speciﬁcally evaluates deposits on pistons for engines with the two-piece steel piston. This te of oil consumption. A second test is conducted with moderate oil soot. The second test measures the fo cylinder liners, and resistance to corrosion. A third new test measures the following characteristics with high l resistance of the oil in plugging the oil ﬁlter, and control of sludge.

In addition to the new tests, API CH-4 oils have tougher limits for viscosity control in applications that gene oxidation resistance. API CH-4 oils must pass an additional test (piston deposit) for engines that use alu also established 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 change intervals. API CH-4 oils are recommended for conditions that demand a premium oil. Your Pe guidelines for optimizing oil change intervals.

iesel engines and in diesel engines that

. API CH-4 oils will generally exceed the

n rings, valve train wear, viscosity control,

w engine tests were developed for the API

st (piston deposit) also measures the control

llowing criteria: wear of piston rings, wear of

evels of soot in the oil: wear of the valve train,

rate high soot. The oils also have improved

minum pistons (single piece). Oil performance is

-4 oils are recommended for use in extended oil

rkins dealer or your Perkins distributor has speciﬁc

ust complete a full test program

ge Guidelines” are not appropriate for

mmercial oil formulations.

rval programs that optimize the life of the

that demand a premium oil. Your Perkins

ines. Also, the oil was designed to

Page 39

SEBU8604 39

Maintenance Section

Reﬁll Capacities

Some commercia

l oils that meet the API classiﬁcations may require reduced oil change intervals. To determine the oil change interval, closely monitor the co

ndition of the oil and perform a wear

metal analysis.

NOTICE

Failuretof

ollow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.

Total Base

Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines

The Total Base Number (TBN) for an oil depends on the fuel sulfur level. For direct injection engines that use disti must be 10 times the fuel sulfur level. The TBN is deﬁned by “ASTM D2896”. The minimum TBN of the oil is 5 r demonstrates the TBN.

llate fuel, the minimum TBN of the new oil

egardless of fuel sulfur level. Illustration 27

NOTICE

Operating Dir

ect Injection (DI) diesel engines with fuel sulphur levels over 0.5 percent will require shortened oil change intervals in order to help maintain adequate wear protecti

Table 19

Percentage of Sulfur in the fuel

Lower than 0.5 Normal

0.5to1.0

Greater than 1.0 0.50 of normal

on.

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

Illustration 27

(Y) TBN by “ASTM 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

Use the following guidelines for fuel sulfur levels that exceed 1.5 percent:

Choose an oil with the highest TBN that meets one

•

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

Reduce the oil 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 analysis.

Excessivepistondepositscanbeproducedbyanoil with a high TBN. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore.

Refer to Table 20 (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.

Table 20

Engine Oil Viscosity

EMA LRG-1

API CH-4

Viscosity Grade

SAE 10W30

E 15W40

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 °F)

Temperatures above

32 °C (89.5 °F)

Synthetic Base S tock Oils

Synthetic base oils are acceptable for use in these engines if these oils meet the performance requirements that are speciﬁed for the engine.

Page 40

40 SEBU8604 Maintenance Section Reﬁll Capacities

Synthetic base conventional oils in the following two areas:

Synthetic bas

•

temperatures especially in arctic conditions.

Synthetic ba

•

stability especially at high operating temperatures.

Some synthe characteristics that enhance the service life of the oil. Perkins does not recommend the automatic extending o oil.

Re-reﬁned

Re-reﬁned base stock oils are acceptable for use in Perk performance requirements that are speciﬁed by Perkins. Re-reﬁned base stock oils can be used exclusiv new base stock oils. The US military speciﬁcations and the speciﬁcations of other heavy equipment manufac stock oils that meet the same criteria.

The proc stock oil should adequately remove all wear metals that are in the used oil and all the additives that areint make re-reﬁned base stock oil generally involves the process of vacuum distillation and hydrotreating the used oi high quality, re-reﬁned base stock oil.

ely in ﬁnished oil or in a combination with

turers also allow the use of re-reﬁned base

he used oil. The process that is used to

l. Filtering is adequate for the production of

oils generally perform better than

eoilshaveimprovedﬂow at low

se oils have improved oxidation

tic base oils have performance

f the oil change intervals for any type of

Base Stock Oils

ins engines if these oils meet the

ess that is used to make re-reﬁned base

Second Choice –

additive package. Although the oil has not been tested for the requirements of the API license, the oil must be either SAE 5W30, or SAE 5W40.

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

Use an oil that has a CH-4

SAE0W20,SAE0W30,SAE0W40,

NOTICE

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 engine's maximum service life or rated performance. Fully formulated, ﬁnished oils consist of base oils and of commercial additive packages. These additive packages are blended into the base oils at precise percentages in order to help provide ﬁnished oils with performance characteristics that meet industry standards.

There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in ﬁnished oil. Aftermarket additives may not be compatible with the ﬁnished oil's additive package, 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.

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

cants for Cold Weather

Lubri

When an engine is started and an engine is operated in amb multigrade oils that are capable of ﬂowing in low 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 bas or with a 5W viscosity grade. Use an oil with a pour point that is lower than −50 °C (−58 °F).

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

First Choice – Use oil with an EMA DHD-1 Re an API license. The oil should be either SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 l

ient temperatures below −20 °C (−4°F),use

e stock multigrade oil with an 0W viscosity grade

llowing lubricants for use in cold weather conditions:

commended Guideline. Use a CH-4 oil that has

ubricant viscosity grade.

Select the correct oil, or a commercial oil that meets

•

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 install a new oil ﬁlter.

Perform maintenance at the intervals that are

•

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

Oil analysis

Oil samples should be taken on a regular basis for the purpose of oil analysis. Oil analysis will complement the preventive maintenance program.

Page 41

SEBU8604 41

Maintenance Section

Reﬁll Capacities

The oil analysi determine oil performance and component wear rates. Contamination can be identiﬁed and measured through the us includes the following tests:

The Wear Rate

•

engine's metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increase in 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 oil's lubricating properties. An infrared analysis is used to c properties of the used oil sample. This analysis allows technicians to determine the amount of deterior also allows technicians to verify the performance oftheoilaccordingtothespeciﬁcation during the entire oi

s is a diagnostic tool that is used to

e of the oil analysis. The oil analysis

Analysis monitors the wear of the

the rate of engine wear metal in the

ompare the properties of new oil to the

ation of the oil during use. This analysis

l change interval.

Page 42

42 SEBU8604 Maintenance Section Maintenance Interval Schedule

i03786359

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 45

Battery or Battery Cable - Disconnect .................. 46

Engine - Cle

Engine Air Cleaner Element - Replace ................. 55

Engine Oil Filter (Auxiliary) - Change ................... 57

Engine Oil S

Fuel System - Prime ............................................. 64

Overhaul (Major) ................................................... 69

Overhaul (

Severe Service Application - Check ..................... 71

Daily

Cooling System Coolant Level - Check ................ 53

Driven Equipment - Check .................................... 54

Engine Ai

Engine Oil Level - Check ...................................... 57

Fuel System Primary Filter/Water Separator -

Drain ................................................................... 66

Walk-Around Inspection ........................................ 74

an ...................................................... 54

ample - Obtain .................................. 58

Top End) ............................................... 69

r Cleaner Service Indicator - Inspect ..... 55

Engine Protect

Governor Actuator - Check ................................... 68

Speed Sensor - Clean/Inspect .............................. 72

Every 7500 Ser

Alternator - Inspect ............................................... 44

Engine Oil Pu

Fuel Transfer Pump (Lift Pump) - Inspect ............. 67

Starting Motor - Inspect ........................................ 73

Turbocharg

Water Pump - Inspect ........................................... 75

ive Devices - Check ...................... 60

vice Hours

mp - Inspect .................................... 58

er - Inspect .......................................... 74

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 49

Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 66

Initial 100 Service Hours

Alternator Pulley - Check ...................................... 44

Engine Valve Lash - Inspect/Adjust ...................... 61

Fan Dr

ive Pulley - Check ...................................... 63

Every 500 Service Hours

e Oil Filter (Auxiliary) - Change ................... 57

Engin

Engine Oil and Filter - Change ............................. 59

Every 500 Service Hours or 1 Year

Actuator Control Linkage - Lubricate .................... 43

Aftercooler Core - Clean/Test ............................... 43

rcooler Core - Inspect ..................................... 44

Afte

Battery Electrolyte Level - Check .......................... 45

Belts - Inspect/Adjust/Replace .............................. 46

ts - Inspect/Adjust/Replace .............................. 47

Bel

Engine Crankcase Breather - Clean ..................... 56

Engine Valve Lash - Inspect/Adjust ...................... 61

l Injector - Inspect/Adjust ................................ 64

Fue

Fuel System Filter - Replace ................................ 65

Hoses and Clamps - Inspect/Replace .................. 68

diator - Clean .................................................... 70

Every Year

oling System Coolant - Change ....................... 51

Engine Mounts - Inspect ....................................... 56

Page 43

SEBU8604 43

Maintenance Section

Actuator Control Linkage - Lubricate

Actuator Control Linkage Lubricate

Illustration 28

Typical examp le

i02471679

g01238418

i03895079

Aftercooler Core - Clean/Test

Personal injury c an result from a ir pressure.

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

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

Note: The core of the aftercooler can not be removed.

The core may be cleaned with a suitable cleaner. The core must be d

1. Pressurized air is the

removing loose debris. Direct the a ir 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.

ry before the engine is operated.

preferred method for

Illustration 29

Typical examp le

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.

2. 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.

3. Back ﬂush the aftercooler with a suitable cleaner.

4. Steam clean the aftercooler in order to remove

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

5. Wash the aftercooler with hot, soapy water. Rinse

the aftercooler thoroughly with clean water.

Page 44

44 SEBU8604 Maintenance Section Aftercooler Core - Inspect

i02322311

Personal injury can result from air pressure.

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

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

6. Dry the aftercooler with compressed air. Direct

the air in the reverse direction of the normal ﬂow. Remove all ﬂuid from the aftercooler. Ensure that the aftercooler is dry.

7. Inspect the aftercooler in order to ensure cleanliness. Pressure test the aftercooler. If necessary, replace the aftercooler.

i03837469

Afterco

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

oler Core - Inspect

Alternator - Inspect

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

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

mends a scheduled inspection of

quipped) during engine operation in

required.

eration. If the batteries are correctly

should be kept warm because temperature

not run for long periods of time or if the

ly than a battery with a full charge.

i03896155

Alternator Pulley - Check

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

. Clean the aftercooler, if necessary.

debris

Personal injury can result from air pressure.

onal injury can result without following prop-

Pers er procedure. When using pressure air, wear a protective face shield and protective clothing.

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

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

Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps,

d seals. Make repairs, if necessary.

1. Isolate the electrical supply to the engine.

Illustration 30

Typical example

g02139698

2. Remove the guard (3) in order to gain access to the drive pulley (1) for the alternator (2).

Note: The bolts (4) are captive.

Page 45

SEBU8604 45

Maintenance Section

Battery - Replace

Illustration 31

Typical examp le

3. Tighten the grub screws (5) to a torque of 20 N·m (15 lb ft).

4. Install the guard (3).

5. Restore the electrical supply to the engine.

g02139714

i023223

Battery - Replace

2. Turn off any bat

battery chargers.

3. The NEGATIVE “ “-” battery termina l 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 terminal.

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 a ny 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 46

46 SEBU8604 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.

i03896240

Belts - Inspect/Adjust/Replace (Alternator Belt)

Inspection

1. Isolate the electrical supply to the engine.

The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before a ny 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 32

Typical example

2. Remove the guard (3).

Note: The bolts (2) are captive.

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

for contamination. If necessary, replace the belt. Refer to “Replacement” for more information.

g02139788

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

Page 47

SEBU8604 47

Maintenance Section

Belts - Inspect/Adjust/Replace

Illustration 33

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 tighten the bolts (2) securely.

6. Restore the electrical supply to the engine.

g01239310

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 t he Alternator Belt

1. If necessary, Isolate the electrical supply to the

engine and remove the guards.

Illustration 34

Typical example

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

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

the engine.

4. Remove the belt (1).

g01239580

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.

i03754170

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

Inspection

1. Isolate the electrical supply to the engine.

Page 48

48 SEBU8604 Maintenance Section Belts - Inspect/Adjust/Replace

2. Loosen the fast

3. Remove the guards (not shown).

Illustration 35

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 24 to 36 N (5.39544 to 8.09316 lb) with a maximum deﬂection at position B of 8 mm (0.314 inch).

eners for the air pipes (not shown).

g02025020

Illustration 36

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

7. Adjust the belts if the belt tension exceeds 36 N

(8.09316 lb). Refer to “Adjustment” for more information.

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

9. Install the guards (not shown).

10. Restore the electrical supply to the engine.

Adjustment

1. If necessary, isolate the electrical supply to the

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

Note: Fandrivebeltsmustbereplacedasaset.Do not replace individual belts.

Removal of the Fan Drive Belts

1. If necessary, isolate the electrical supply to the

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

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 the belts (1) over the pulleys.

Page 49

SEBU8604 49

Maintenance Section

Cooling System Coolant (ELC) - Change

2. Rotate the rod ( tension of belts (1). The total deﬂection should not exceed 12.5 mm (0.5 inch).

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

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

3) in order to achieve the correct

guards.

i03837530

Cooling System Coolan t (ELC)

- Change

NOTICE Care must be taken to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adj collect the ﬂuid with suitable containers before opening any compartment or disassembling any component con

Dispose of all ﬂuids according to Local regulations and mandat

Keep all parts clean from contaminants.

usting and repair of the product. Be prepared to

taining ﬂuids.

es.

NOTICE

Drain

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

Illustration 37

Typical example

1. Stop th Loosen the cooling system ﬁller cap (1) slowly in order to relieve any pressure. Remove the cooling system

ystem: Hot coolant can cause seri-

re cool. Loosen the cooling system

g0 1 2111

e engine and allow the engine to cool.

ﬁller cap.

Contaminants may cause rapid wear and shortened component life.

Clean the cooling system and ﬂush the cooling system before the recommended maintenance

rval if the following conditions exist:

inte

The engine overheats frequently.

•

Foaming of the coolant is observed.

•

oil has entered the cooling system and the

The

•

coolant is contaminated.

e fuel has entered the cooling system and the

•

coolant is contaminated.

te: 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

een drained. This is a good opportunity to replace

b the water pumps, the water temperature regulators and the hoses, if necessary.

Illustration 38

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.

g0 1 21116 0

Page 50

50 SEBU8604 Maintenance Section Cooling System Coolant (ELC) - Change

Illustration 39

Typical examp le

g01211161

4. Open the drain cocks or remove the drain plugs (3) in the oil coolers.

For informatio

n 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 t the drain cocks or install the drain plugs (3) in the oil coolers. Install the drain plugs (5) in the aftercoole

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

Cooling system air locks may result in engine damage.

3. Fill the cooling system with clean water.

Loosen t cooling system until coolant free of air ﬂows from the vent . Tighten the air vent securely.

he drain plug on the radiator. Close

rs. Tighten the plugs securely.

NOTICE

l) per minute to avoid air locks.

he air vent (4) in the aftercoolers. Fill the

Illustration 40

Typical examp le

g02126488

Note: In some application, opening the air vent (4) will assist the draining of the coolant.

5. 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.

Install the cooling system ﬁller cap (1).

4. Start t

he engine. Operate the engine until the

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

5. Stop t

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

m ﬁller cap. Open the drain cock or remove

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

ator. Open the drain cocks or remove the drain

radi plugs (3) in the oil coolers. Remove both the drain plugs (5) in the aftercoolers. Allow the water to

n. Flush the cooling system with clean water.

drai

Fil

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

cylinder block. Close the drain cock or install

the the drain plug on the radiator. Close the drain cocks or install the drain plugs (3) in the oil coolers.

stall 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.

Page 51

SEBU8604 51

Maintenance Section

Cooling System Coolant - Change

2. Fill the coolin Coolant (ELC). Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Mainte on cooling system speciﬁcations.

Note: Open th be removed from the system. Fill t he cooling system until coolant free of air ﬂows from the vent . Tighten the air vent installed before operating the engine.

3. Start the en purge the air from the cavities of the engine block. Use the normal shutdown procedure in order to stop the en

Illustration 41

Typical examp le

g system with Extended Life

nance Section) for more information

eairvent(4)inordertoallowairto

securely. Ensure that the ﬁller cap is

gine. Operate the engine in order to

gine.

g01239656

i03837649

Cooling System Coolant Change (Inhibitor)

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

Dispose of all ﬂuids according to Local regulations and mandates.

NOTICE Keep all

Contaminants may cause rapid wear and shortened compone

parts clean from contaminants.

nt life.

4. Remove the ﬁller cap. Check that the coolant level is within 25 mm (1.0 inch) of the bottom of the ﬁller pipe. 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.

5. Install the cooling system ﬁller cap.

6. Start the engine and operate the engine.

Inspect the cooling system for leaks. Ensure that the cooling system operates at the correct temperature.

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

The engine overheats frequently.

•

Foaming of the coolant is observed.

•

The oil has entered the cooling system and the

•

coolant is contaminated.

The fuel has entered the cooling system and the

•

coolant is contaminated.

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

Page 52

52 SEBU8604 Maintenance Section Cooling System Coolant - Change

Drain

Pressurized S

ystem: Hot coolant can cause serious burns. To open the cooling system ﬁller cap, stop the engine and wait until the cooling system components a

re cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

Illustration 42

Typical examp le

1. Stop th

e engine and allow the engine to cool.

g012111

Loosen the cooling system ﬁller cap (1) slowly in order to relieve any pressure. Remove the cooling system

ﬁller cap.

Illustration 44

Typical example

g0 1 21116 1

4. Open the drain cocks or remove the drain plugs (3) in the oil coolers.

Illustration 43

Typical examp le

g01211160

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.

Illustration 45

Typical example

g02126488

Note: In some application, opening the air vent (4) will assist the draining of the coolant.

5. Remove both 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.

Page 53

SEBU8604 53

Maintenance Section

Cooling System Coolant Level - Check

Flush

1. Flush the cool

to remove any debris.

2. Close the drai the cylinder block. Close the drain cock or install the drain plug on the radiator. Close the drain cocks or inst Close the drain cocks or install the drain plugs (5) in the aftercoolers. Tighten the plugs securely.

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 c

Loosen the air vent (4) in the aftercoolers. Fill the cooling the vent . Tighten the air vent securely.

the cooling system ﬁller cap (1).

Install

4. Start the engine. Operate the engine until the temper

5. Stop the engine and allow the engine to cool. Loosen in order to relieve any pressure. Remove the cooling system ﬁller cap. Open the drain cock or remov Open the drain cock or remove the drain plug on the radiator. Open the drain cocks or remove the drain plugs (5) in the aftercoolers. Allow the water to drain. Flush the cooling system with clean water.

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

e the drain plug (2) in the cylinder block.

plugs (3) in the oil coolers. Remove the drain

ing system with clean water in order

n cock or install the drain plug (2) in

all the drain plugs (3) in the oil coolers.

NOTICE

ooling system with clean water.

system until coolant free of air ﬂows from

the cooling system ﬁller cap (1) slowly

Fill

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

the cylinder block. Close the drain cock or install

drain plug on the radiator. Close the drain

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

Note: Open the a be removed from the system. Fill the cooling system until coolant free of air ﬂows from the vent . Tighten the air vent se installed before operating the engine.

3. Start the eng purge the air from the cavities of the engine block. Use the normal shutdown procedure in order to stop the eng

4. Check that the coolant level is within 25 mm (1.0 inch) o

Illustration 46

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 operate the engine. Inspect the cooling system for leaks. Ensure that the cooling system operates at the correct temperature.

ir vent (4) in order to allow air to

curely. Ensure that the ﬁller cap is

ine. Operate the engine in order to

ine.

f the bottom of the ﬁller pipe.

g01239656

i02415245

Cooling Sys tem Coolant Level

- Check

TICE

NO 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.

ill the cooling system with water and inhibitor.

2.F

Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Maintenance

ection) for more information on cooling system

S speciﬁcations.

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

Page 54

54 SEBU8604 Maintenance Section Driven Equipment - Check

Illustration 47

1. Remove the cooling system ﬁller cap (1) slowly in

order to relieve pressure.

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

of the bottom of the ﬁller pipe.

Illustration 48

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.

g01211179

g01239656

Other maintena

•

Perform any maintenance for the driven equipment which is recom

nce recommendations

mended by the OEM.

i02415247

Engine - Clean

Personal injury o r death can result from high voltage.

Moisture can create paths of electrical conductivity.

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

NOTICE Accumulatedgreaseandoilonanengineisaﬁre hazard. Keep the engine clean. Remove debris and ﬂuid

whenever a signiﬁcant quantity accumulates on

spills the engine.

NOTICE Water or condensation can cause damage to generator components. Protect all electrical components from exposure to water.

NOTICE Failure to protect some engine components from washing may make your engine warranty invalid. Allow the engine to cool for one hour before washing the engine.

4. Inspect the cooling system for leaks.

i02151646

Driven Equipm ent - Check

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

Inspection

•

Adjustment

•

Lubrication

•

Periodic cleaning of the engine is recommended. A clean engine provides the following beneﬁts:

Easy detection of ﬂuid leaks

•

Maximum heat transfer characteristics

•

Ease of maintenance

•

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

Page 55

SEBU8604 55

Maintenance Section

Engine Air Cleaner Element - Replace

i03781216

Engine Air Clean er 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.

“Engine Air cleaner Service Indicator -

3. Install a new el Align the cover (3) to the housing (1). Secure the clips (3).

ement (2) into the housing (1).

i02415251

Engine Air C lean er Service Indicator - Inspect

Service Indicator Check

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

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

Illustration 49

gines are equipped with air intake

rt does not enter the housing of the air cleaner.

g02041313

Illustration 50

When t condition, the center section of the service indicator (1) is clear.

Illustration 51

he air ﬁlter element is in a serviceable

g01242320

g01242332

1. Release the clips (3) and remove cover (4).

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

Discard the old element.

Note: Ensure that dirt does not enter the housing.

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

Page 56

56 SEBU8604 Maintenance Section Engine Crankcase Breather - Clean

Service Indicator Reset

ion 52

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

i03874496

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.

Illustration 53

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.

7. Align the cover (2) with the dowel (4). Install the cover to the breather body (5).

g02117753

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

9. Restore the electrical supply to the starting motor.

i02415257

Engine Mo unts - Inspect

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

Improper mounting

•

Page 57

SEBU8604 57

Maintenance Section

Engine Oil Filter (Auxiliary) - Change

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.

Replace any more information, see the literature that is provided by the OEM of the isolators.

the bolts for the isolators are tightened to

isolator that shows deterioration. For

i02472513

Engine Oil Filter (Auxiliary) Change

Note: Refer to the Operation and Maintenance

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

Change the Filter with the Engine in Operation

The changeover

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

•

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

•

1. Rotate the changeover valve to position B. By using a suit oil ﬁlter.

Note: Oil ﬂo

2. Ensure that the sealing face on the housing is

clean. Fil 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 only in order to install the oil ﬁlter. Rotate the changeover valve to position A. Check for oil leaks.

5. Clean any spillage of engine oil.

valve (1) has three positions.

w is to the right hand oil ﬁlter.

able tool (2), remove the right hand

w direction (D and E ).

l the new oil ﬁlter with clean engine oil.

he new oil ﬁlter. Apply hand pressure

l and hot components can cause personal

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

Illustration 54

Typical examp le

g01233078

i02415261

Engine Oil Level - C heck

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.

Page 58

58 SEBU8604 Maintenance Section Engine Oil Pump - Inspect

i02415262

Engine Oil Sample - O btain

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

program.

Illustration 55

Illustration 56

(Y) “Min” mark. (X) “Max” mark.

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.

g01236968

g01165836

Initiating

an Oil analysis Program

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.

Note: Pe maintenance schedule.

ne continues to operate the levels will

Hours

l sampling. Each individual operator can

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.

i03883009

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. Replace any components that are worn or damaged. Alternatively, replace the engine oil pump.

il sample must be taken f rom 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, recordthefollowinginformationbeforeanoilsample

aken:

is t

The date of the sample

•

Engine model

•

gine number

•

Service hours on the engine

•

The number of hours that have accumulated since

•

the last oil change

Page 59

SEBU8604 59

Maintenance Section

Engine Oil and Filter - Change

Theamountofoi

•

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.

can be checked for the following: the

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

i03895137

il and Filter - Change

Failure to foll cause the waste particles to be recirculated through the engine lubrication system with the new oil.

ow this recommended procedure will

Drain the Engine Lubricating Oi l

Illustration 57

Typical example

1. Place a suitable container below the engine oil pan. Remove the drain plug (3). Allow the engine oil to drain.

g01237431

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

raining cold oil. Drain the oil pan with the engine

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.

Note: Ensurethatthevesselthatwillbeusedislarge 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).

Replace the Oil Filter

Table 21

Required Tools

Tool

Perkins oil ﬁlters are manufactured to Perkins Engine Company LTD speciﬁcations. Use of an oil ﬁlter 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

Page 60

60 SEBU8604 Maintenance Section Engine Protective Devices - Check

Illustration 58

Typical examp le

g01237432

1. UseTooling(A)inordertoremovetheoilﬁlters (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.

3. Start the engin

e and run the engine for two minutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil ﬁlters are ﬁll

ed. Inspect the oil ﬁlters for oil leaks.

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

Illustration 59

” mark. (X) “Max” mark.

(Y) “Min

r a minimum of ten minutes.

g01165836

5. Remove the engine oil level gauge (2) in order to check th

e oil level. Maintain the oil level between the “MIN” and “MAX” marks on the engine oil level gauge.

i02461963

Engine Protective Devices Check

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 auxilliary oil ﬁlter system or a remote ﬁlter system, follow the OEM or the ﬁlter manufacture's remonmendations. 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.

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.

Page 61

SEBU8604 61

Maintenance Section

Engine Valve Lash - Inspect/Adjust

To prevent dama

ge to the engine, only authorized service personnel or your Perkins dealer should perform the tests.

Visual Inspection

Visually check the condition of all gauges, sensors and wiring. Look for wiring and components that are loose, br

oken, or damaged. Damaged wiring or components should be repaired or replaced immediately.

i03783810

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

Table 22

Required Tools

Too l

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

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

Ensure that the engine can not be started while this maintenance is being performed. To help prevent possible i njury, 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.

Part

Number

SE253

Part Name

Crankshaft Turning Tool 1

Feeler Gauges 1

Qty

NOTICE

Illustration 60

g01241573

1. Remove t he setscrews (1).

2. Remove the rocker cover (2).

3. Remove the joint (not shown).

4. Repeat Steps 1 through 3 for the remaining rocker

covers.

For 4016 engines, set the valve lash in the sequence that is shown in the Table 23.

Table 23

4016 Engines

Piston at T.D.C.

A1 & A8

B1 & B8 B8 B1

A3 & A6 A6 A3

B3 & B6 B6 B3

A7 & A2 A2 A7

B7 & B2 B2 B7

A5 & A4 A4 A5

B5 & B4 B4 B5

&A8 A1 A8

B1 & B8

A3 & A6

B3 & B6

A7 & A2

B7 & B2 B7 B2

A5 & A4 A5 A4

B5 & B4 B5 B4

Valves o n t he

Rock

A8 A1

B1 B8

A3 A6

B3 B6

A7 A2

Check and

Adjust Valves.

Page 62

62 SEBU8604 Maintenance Section Engine Valve Lash - Inspect/Adjust

Illustration 61

4016 Engine

Illustration 62

Typical examp le

g01241941

g01241570

5. Use Tooling (A) in order to rot ate the crankshaft

until the appropriate mark (4) on the ﬂywheel is in alignment with the pointers (3). Ensure that there is clearance between the rocker arm and the valve.

Illustration 63

g01241584

6. Loosen the locknut (7) on the inlet valve bridge.

7. In order to equalize the bridge, turn the adjuster

(6) until the ﬁxed pad on the valve bridge (5) and the adjuster is in contact with the valve.

8. Tighten the locknut (7) to a torque of 50 N·m (37 lb ft).

9. Repeat Steps 6 through 8 for the exhaust valve bridge.

Note: The timing window is located in the ﬂywheel housing of B bank.

Illustration 64

g01241598

10. Use Tooling (B) in order to check the valve lash. If necessary, follow Steps 10.a through 10.f in order to adjust the valve lash. Set the valve lash to 0.4 mm (0.016 inch).

Page 63

SEBU8604 63

Maintenance Section

Fan Drive Pulley - Check

a. Loosen the lock

nut (9) on the rocker arm of the

inlet valve.

b. Use Tooling (B

) in order to set the valve lash.

c. Turn the adjuster (8) until the pad on the rocker

arm is in cont

act with Tooling (B).

d. Tighten the locknut (7) to a torque of 50 N·m

(37lbft).

e. Ensure that the valve lash is correct.

f. Repeat Step 10 for the rocker arm of the

exhaust valve.

11. Repeat Steps 5 through 10 for the remaining rockers.

Illustration 66

Typical example

g01238304

2. Remove the guards (not shown) in order to gain access to the fan drive pulley (1).

Illustration 65

g01241917

12. Ensure that the rocker cover (2) is clean and free from damage. Ensure that the joint face of the rocker base (10) is clean and free from damage.

13. Install a new joint (not shown).

14. Install the rocker cover (2).

15. Install the setscrews (1). Tighten the setscrews to

a torque of 4 N·m (35 lb in).

16. Repeat Steps 12 through 15 for the remaining rocker covers.

i02463729

Fan Drive Pulley - Check

1. Isolate the electrical supply to the engine.

Illustration 67

g01238305

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.

Page 64

64 SEBU8604 Maintenance Section Fuel Injector - Inspect/Adjust

i03784609

Fuel Injector - Inspect/Adjust

Inspect the Fuel Injectors

Refer to Syst KENR9224, “Fuel Injector Adjustment” for information on inspection of the fuel injectors.

em Operation,Testing and Adjusting ,

i02415266

Fuel System - Prime

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

The fuel day tank is empty or partially drained.

•

The low pressure fuel lines are disconnected.

•

A leak exists in the low pressure fuel system.

•

The fuel ﬁlter has been replaced.

•

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

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

Illustration 68

Typical example

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

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).

g01280510

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.

Illustration 69

Typical example

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).

g01237503

Page 65

SEBU8604 65

Maintenance Section

Fuel System Filter - Replace

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 c ylinde

r is now primed. An amount of fuel will

have reached the remaining cylinders.

13. Push the ha

ndle and twist the handle in order to

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 purgetheremainingairfromthefuelsystem.

i03837989

2. Place a suitabl

e container under the fuel ﬁlter in

order to catch any fuel that might spill.

Note: Clean up

Illustration 70

any spilled fuel immediately.

g02126034

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. Clean up fuel spills immediately.

NOTICE

Ensure that the engine is stopped before any servicing

pair is performed.

or re

Fuel Filter with Water Separator

Table 24

Required Tools

Tool

Part

Number

Part Name

Strap Wrench 1

Qty

3. Loosen the drain plug (2). Allow the ﬂ uid to drain

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.

Note: Two fuel ﬁlters are installed. Both fuel ﬁlters must be replaced at the same time.

1. Isolate the fuel supply to the engine.

Page 66

66 SEBU8604 Maintenance Section Fuel System Primary Filter/Water Separator - Drain

i03880440

Fuel System Primary Filter/Water

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

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

ne operation. Ensure that the drain valve is

Separator - Drain

NOTICE

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.

Fuel Tank

Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel can cause excessive wear to the fuel system.

Water can be introduced into the fuel tank when the fuel tank is being ﬁlled.

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

Note: Clean up any spilled fuel immediately.

Illustration 71

2. Loosen the drain plugs (1). Allow the ﬂuidtodrain into the container until clean fuel can be seen.

g02126453

Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.

Drain the Water and the Sediment

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

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

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

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

3. Tighten the drain plugs (1). Use hand pressure only. Dispose of the drained ﬂuid in accordance with local regulations.

Page 67

SEBU8604 67

Maintenance Section

Fuel Transfer Pump (Lift Pump) - Inspect

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

use supply pipes that allow water

ctly 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

•

Service int

•

Reﬁll of the tank

•

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

If a bulk storage tank has been reﬁlled or moved recently settle before ﬁlling the engine fuel tank. Internal bafﬂes in the bulk storage tank will also help trap sedimen storage tank helps to ensure the quality of the fuel. When possible, water separators should be used.

ervals

, allow adequate time for the sediment to

t. Filtering fuel that is pumped from the

Illustration 72

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

i02471681

Fuel Transfer Pump (Lift Pump)

- Inspect

ally inspect the lift pump for leaks. The lift pump

Visu is not a serviceable item. Replace a lift pump that is faulty. Replace a lift pump that leaks.

Replacement of the L ift Pump

Removal of the Lift Pump

late the fuel supply to the lift pump.

1. Iso

2. Place a suitable container below the lift pump in

der to catch any fuel that might be spilled.

Note: Clean up any spillage of fuel immediately.

6. Remove the fuel lift pump (2).

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

the joint.

Installation of the Lift Pump

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

2. Alignthedrivefortheliftpump(2).Installthelift

pump.

Note: Ensure that the oil seal is not damaged as the lift pump is installed.

3. Install the nuts (4). Tighten the nuts to a torque of 25 N·m (18 lb ft).

4. Remove the cap from the fuel line (3). Connect 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.

7. Remove the air from the fuel system. Refer to

Operation and Maintenance Manual, “Fuel System

- Prime”.

Page 68

68 SEBU8604 Maintenance Section Governor Actuator - Check

i02471680

Governor Actuator - Check

In order for th control box must be calibrated to the actuator. The feedback parameters from the control box must correspond t actuator. Carry out a periodic calibration check of the governor system. Refer to Special Instruction, “Pandoras D

e governor to operate correctly, the

o the 0% and the 100% positions on the

igital Governor” for more information.

i02349879

Hoses and Clamps Inspect/Replace

Contact penetration and burn hazards. High pressure fuel spray may cause a ﬁre hazard. Failure to follow the structions may ca use personal injury or death.

If you i the proper inspection procedure in order to avoid a ﬂuid penetration hazard. Refer to Operation and Maint

with high pressure fuel may cause ﬂuid

se inspection, maintenance and service in-

nspect the engine in operation, always use

enance Manual, “General hazard Information”.

A constant torq of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard clamp.

Due to extreme temperature changes, the hose will harden. Hard clamps to loosen. This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps.

Each installation application can be different. The difference

Type of hose

•

Type of ﬁtting material

•

Anticipat

•

Anticipated expansion and contraction of the

•

ﬁttings

Replace t

Refer to the OEM information for further information on remov

The coolant system and the hoses for the coolant system a following text describes a typical method of replacing coolant hoses. Refer to the OEM information for

r information on the coolant system and the

furthe hoses for the coolant system.

ue hose clamp can be used in place

ening of the hoses will cause hose

s depend on the following factors:

ed expansion and contraction of the hose

he Hoses and the Clamps

ing and replacing fuel hoses (if equipped).

re not usually supplied by Perkins. The

Inspect all hoses for leaks that are caused by the

wing conditions:

follo

Cracking

•

Softness

•

eclamps

Loos

•

Replace hoses that are cracked or soft. Tighten any

se clamps.

loo

Check for the following conditions:

End ﬁttings that are damaged or leaking

•

ter covering that is chafed or cut

•

Exposed wire that is used for reinforcement

•

Outer covering that is ballooning locally

•

lexible part of the hose that is kinked or crushed

•

Armoring that is embedded in the outer covering

•

Pressurized System: Hot coolant can cause serious bu stop the engine and wait until the cooling system components are cool. Loosen the cooling system pres sure.

1. Stop

2. Loosen the cooling system ﬁller cap slowly in

container. The coolant can be reused.

3. Dr

4. Re

5. Disconnect the old hose.

rns. To open the cooling system ﬁ ller cap,

sure cap slowly in order to relieve the pres-

the engine. Allow the engine to cool.

er to relieve any pressure. Remove the cooling

ord system ﬁller cap.

te: Drain the coolant into a suitable, clean

ain the coolant from the cooling system to a

level that is below the hose that is being replaced.

movethehoseclamps.

Page 69

SEBU8604 69

Maintenance Section

Overhaul (Major)

6. Replace the old

7. Install the hose clamps with a torque wrench.

Note: For the correct coolant, see this Operation and

Maintenance Manual, “Fluid Recommendations”.

8. Reﬁll the cooling system. Refer to the OEM information for further information on reﬁlling the cooling sys

9. Clean the cooling system ﬁller cap. Inspect the cooling sys cooling system ﬁller cap if the seals are damaged. Install the cooling system ﬁller cap.

10. Start the engine. Inspect the cooling system for leaks.

hose with a new hose.

tem.

tem ﬁller cap's seals. Replace the

i02461950

Overhaul (Major)

Scheduling a Major Overhaul

The need several factors:

for a major overhaul is determined by

Note: The drive when the engine is overhauled. Refer to the literature that is provided by the OEM of the driven equipment.

n equipment may also require service

Major Overhaul Information

During a major overhaul, all of the bearings, seals, joints, and components that wear should be disassemble parts should then be inspected. If necessary, the parts should be replaced. The crankshaft should be inspected a may require regrinding. Alternatively, the crankshaft may be replaced.

Inspecting Components

Inspect th overhaul.

Engine mo

•

Camshafts

•

Camshaft followers

•

Connect

•

Crankshaft and bearings

•

d. The parts should be cleaned. The

nd measured for wear. The crankshaft

e following components during a major

unted aftercoolers

ing rods and bearings

An incr

•

An increase of crankcase blowby

•

A decrease and variation of cylinder compression

•

Other a major overhaul:

The se

•

The wear metal analysis of the lube oil

•

An increase in the levels of noise and vibration

•

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

Not

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

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

oc the wear metals.

ease of oil consumption

factors must also be considered for determining

rvice hours of the engine

crease of wear metals in the lube oil indicates

se and vibration indicates that rotating parts

e: It is possible for oil analysis to indicate a

Gear train

•

ir piping

Inlet a

•

Oil cooler

•

Pistons and rings

•

der liners

Cylin

•

Replace the crankshaft vibration damper.

i03880466

Overhaul (Top End)

eduling a Top End Overhaul

Sch

Top end overhauls should be scheduled according to

e recession of the valve stems. This measurement

th provides an accurate indication of the rate of valve wear.Thismeasurementcanbeusedtopredictwhen

ylinder head requires replacement.

nitor the engine as the engine accumulates

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

Page 70

70 SEBU8604 Maintenance Section Radiator - Clean

Note: Generall

y, cylinder heads wear out at different rates. In some cases, servicing the cylinder heads at different times may be the most economic decision. This depends o

nthevalvestemprojectionofthe individual cylinders. However, this decision must include the costs of additional downtime that is caused by thi

s procedure. Perform an economic analysis in order to determine if cylinder heads should be serviced as a group or divided into smaller groups.

Top End Overhaul Information

A top end overhaul involves servicing the cylinder heads. During a top end overhaul, one piston should be removed. cylinder liner. The condition of these components will determine the period of the major overhaul.

Monitoring Valve Seat Wear

Every 500 monitoring of the valve seat wear should be carried out before any adjustment of the valve lash.

1. Remove the rocker covers.

2. Refer to

“Valve Lash - Inspect Adjust”.

3. On all en

before any adjustments are made.

Inspect the piston, piston rings and the

service hours record the valve lash. The

Operation and Maintenance Manual,

gine cylinders, record the clearance

After 4000 hour

s running, the valve seat wear on

the inlet is 0.65 mm (0.026 inch) and the exhaust is

0.45 mm (0.018 inch).

Note: Maximum permitted valve seat wear is

1.00 mm (0.040 inch).

In this example, the valves are still serviceable after 4000 hours running.

When the valves approach the maximum wear limit, the rockers can be removed and a measurement from the cyl

inderheadfacetothetopofthevalve stems can be taken. When a new valve is installed the protrusion of the valve stem would be 29.75 mm (1.171 inc

h). therefore, a maximum wear limit would

be 30.75 mm (1.211 inch).

i02415302

Radiator - Clean

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

Inspect the radiator for these items: Damaged ﬁns, corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the radiator, if necessary.

4. Set t he

valve bridges.

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

The recorded values can be used to identify any excessive valve seat wear on individual valves. The

ded values can be used to schedule a top end

recor overhaul.

ample of recorded valve lash

An ex

Table 25

Recorded

rances on A1

clea cylinder

Hours Inlet Exhaust Inlet Exhaust

500 0.4

1000 0.4 0.4 0 0

1500 0.35 0.35 0.05 0.05

2500 0.3 0.3 0.2 0.2

3000 0.25 0.3 0.35 0.3

500

4000 0.25 0.3 0.65 0.45

.25

0.4

.35

Tot a l val v e we a r

.35

Personal injury c an result from a ir pressure.

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

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

Pressurized air is the preferred method for removing loosedebris.Directtheairintheoppositedirection to the fan's air ﬂow. Hold the nozzle approximately 6 mm (0.25 inch) away from the radiator ﬁns. Slowly move the air nozzle in a direction that is parallel with the radiator tube assembly. This will remove debris that is between the tubes.

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

Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water.

Page 71

SEBU8604 71

Maintenance Section

Severe Service Application - Check

After cleaning engine. This will help in the removal of debris and the drying of the core. Stop the engine. Use a light bulb behind th cleanliness. Repeat the cleaning, if necessary.

Inspect the ﬁ with a “comb”. Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps, and

the radiator, start the engine. Run the

ecoreinordertoinspectthecorefor

ns for damage. Bent ﬁns may be opened

seals. Make repairs, if necessary.

i02335775

Severe Service Application Check

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

Performance such as power range, speed range,

•

and fuel consumption

Fuel quality

•

Operational Altitude

•

Theoperatinge procedures and incorrect maintenance procedures can be factors which contribute to a severe service application.

Environmenta

Ambient temperatures – Theenginemaybe

exposed to ex cold environments or hot environments. Valve components can be damaged by carbon buildup if the engine i cold temperatures. Extremely hot intake air reduces engine performance.

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

Buildup – Compounds, elements, corrosive chemical

Altitude – Problems can arise when the engine is operate settings for that application. Necessary adjustments should be made.

orrosive chemicals.

s and salt can damage some components.

d at altitudes that are higher than the intended

nvironment, incorrect operating

l Factors

tended operation in extremely

s frequently started and stopped in very

sty, unless the equipment is cleaned

Maintenance intervals

•

Oil selection and maintenance

•

Coolant type and maintenance

•

Environmental qualities

•

Installation

•

The temperature of the ﬂuid in the engine

•

Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the deﬁned parameters.

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

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

Incorrect Operating Procedures

Extended operation at low idle

•

ent hot shutdowns

Frequ

•

Operating at excessive loads

•

Operating at excessive speeds

•

ting outside the intended application

Opera

•

rrect Maintenance P rocedures

Inco

Extending the maintenance intervals

•

Failure to use recommended fuel, lubricants and

•

coolant/antifreeze

Page 72

72 SEBU8604 Maintenance Section Speed Sensor - Clean/Inspect

i03896257

Speed Sensor - Clean/Inspect (Engine Speed

Sensor and

Overspeed Sensor)

When the engine is cranked, small metal particles are produce magnetic end of the crankshaft position sensor and the overspeed sensor. Contamination will distort the signals sensors should be regularly cleaned and adjusted in order to ensure a good signal.

Table 26

Too l

A SE253 Crankshaft Turning Tool 1

Engine Speed Sensor

d. These particles will contaminate the

that are produced by the sensors. The

Required T

Part

Number

ools

Part Name Qty

4. Use a soft, dry c

from the sensor (2).

Note: Do not us 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 the tapped hole.

6. By hand, car

contact is made with the ring gear.

Note: Do no

t tighten the sensor.

loth in order to clean any debris

eawirebrushinordertocleanthe

h on the ring gear with the center of

efully install the sensor (2) until light

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

1. Isolate the electrical supply to the engine.

Illustration 73

Typical examp le

g01237852

Illustration 74

7. Unscrew the sensor (2) by half of one full 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.

g01237854

Overspeed Sensor

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

1. Isolate the electrical supply to the engine.

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

(1).

3. Remove the sensor (2).

Page 73

SEBU8604 73

Maintenance Section

Starting Motor - Inspect

Illustration 75

Typical examp le

g01237853

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

3. Remove the sensor (2).

7. Unscrew the sen

sor (2) by half of one full 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.

i03882553

Starting Motor - Inspect

If a starting motor fails, the engine may not start in an emergency situation. A scheduled inspection of the starting motors is recommended.

Note: Problems with the electric starting motor can be caused by the following conditions: malfunction of the solenoid and malfunction of the electric starting system.

Inspect the electrical system for the following conditions:

4. Use a soft, dry cloth in order to clean any debris from the sensor (2).

Note: Donotuseawirebrushinordertocleanthe 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.

Loose connections

•

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 properly. The engine will not start if the starting motor pinion does not engage the ﬂywheel ring gear. The teeth of the starting motor pinion and the ﬂywheel ring gear can be damaged because of irregular engagement.

Inspect the starting motors for proper operation. Listen for grinding when the engine is started. Inspect the teeth of the starting motor pinions and the ﬂywheel ring gear. Look for patterns of wear on the teeth. Look for teeth that are broken or chipped. If damaged teeth are found, the starting motor pinions and the ﬂywheel ring gear must be replaced.

Illustration 76

g01237854

Page 74

74 SEBU8604 Maintenance Section Turbocharger - Inspect

i03837996

Turbocharger - Inspect

Periodic insp for the turbochargers. Fouling of the turbine wheels can contribute to loss of engine power and overall loss of engin

If a turbocharger fails during engine operation, damage to th and/or to the engine may occur. Damage to a turbocharger compressor wheel could allow parts from the co cylinder. This can cause additional damage to the pistons, the valves, and the cylinder head.

Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems. Loss of en damage.

Minor le tended low idle operation should not cause problems as long as a turbocharger bearing failure has not occurred.

When a turbocharger bearing failure is accompanied by a sig smoke or engine rpm up at no load), do not continue engine operation until the turbocharger is repaired or

ced.

repla

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 balancedduetohighrpm.

ection and cleaning is recommended

eefﬁciency.

e turbocharger compressor wheel

mpressor wheel to enter an engine

NOTICE

gine lubricant can result in serious engine

akage of a turbocharger housing under ex-

niﬁcant engine performance loss (exhaust

2. Turn the compre by hand. The assembly should turn freely. Inspect the compressor wheel and the turbine wheel for contact with t should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharge contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing, the turboch

3. Check the compressor wheel for cleanliness. If only the i and/or moisture is passing through the air ﬁltering system. If oil is found only on the back side of the wheel, the oil seal.

The presen engine operation at no load. The presence of oil may also result from restriction of the inlet air (plugged the seal for the turbocharger compressor.

Note: Dep on the turbine wheel. Turbine wheel will become unbalanced when the deposits ﬂake off. The turboch occurs. However, remove deposits from the housing. This will prevent wear on the blades of the new turbine

4. Inspect the turbine wheel and the housing for deposi (0.06 inch) thickness are found or if the turbine is in contact with the housing, the turbocharger must b the deposits can be difﬁcult.

5. Inspe corrosion and deposits.

6. Clea standard shop solvents and a soft bristle brush.

air ﬁlters). This causes oil to leak past

osits of ash and silicone can accumulate

arger cartridge must be replaced when this

wheel.

ts of ash and silicone. If deposits of 1.6 mm

e disassembled and cleaned. Removal of

cttheboreoftheturbinehousingfor

n the turbocharger compressor housing with

ssor wheel and the turbine wheel

he turbocharger housing. There

r housing. If there is any indication of

arger should be reconditioned.

nlet side of the wheel is dirty, dirt

re is a possibility of a failed turbocharger

ce of oil may be the result of extended

The following conditions can cause a turbocharger to be out-of-balance:

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, consult a Perkins dealer or 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.

7. Fast

en 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.

Page 75

SEBU8604 75

Maintenance Section

Water Pump - Inspect

For maximum eng inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose b trash buildup. Make repairs, as needed:

The guards mu

•

damaged guards or replace missing guards.

Wipe all cap

•

serviced in order to reduce the chance of system contamination.

For any typ ﬂuid. If leaking is observed, ﬁnd the source and correct the leak. If leaking is suspected, check the ﬂuid levels more often 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.

e of leak (coolant, lube, or fuel) clean up the

than recommended until the leak is found

ine service life, make a thorough

olts, worn belts, loose connections and

st be in the correct place. Repair

s and plugs before the engine is

NOTICE

Inspect the wir

•

Belts for multiple groove pulleys must be replaced as matched sets. carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt c

Water Pump -

A failed water pump may cause severe engine overheating problems that could result in the following condition

Cracks in the cylinder head

•

Apistonseizure

•

Other pot

•

Note: The water pump seal is lubricated by the coolant amount of leakage to occur as the engine cools down and parts contract.

Visually inspect the water pumps for leaks. The water pumps are not serviceable items. Replace a leaking water p

in the cooling system. It is normal for a small

ump.

ing harness for damage.

If only one belt is replaced, the belt will

ould cause the belt to break.

i03882689

Inspect

ential damage to the engine

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.

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.

Page 76

76 SEBU8604 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 77

SEBU8604 77

Index Section

Index

Actuator Con

After Stopping Engine............................................ 29

Aftercooler Core - Clean/Test ................................ 43

Aftercoole

Alternator - Inspect ................................................ 44

Alternator Pulley - Check ....................................... 44

Battery - Replace................................................... 45

Battery Electrolyte Level - Check .......................... 45

Battery or

Before Starting Engine .................................... 10, 26

Belts - Inspect/Adjust/Replace (Alternator Belt) .... 46

Adjustme

Inspection........................................................... 46

Replacement...................................................... 47

Belts - I

Adjustment ......................................................... 48

Inspection........................................................... 47

Replace

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

Batteries............................................................... 7

Coolan

Oils....................................................................... 7

Cold W

Cooling System Coolant - Change (Inhibitor) ........ 51

Drain .................................................................. 52

Fill ...................................................................... 5

Flush .................................................................. 53

Cooling System Coolant (ELC) - Change.............. 49

n .................................................................. 49

Drai

Fill ...................................................................... 50

Flush .................................................................. 50

ing System Coolant Level - Check ................. 53

Cool

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

ven Equipment - Check..................................... 54

Dri

trol Linkage - Lubricate ..................... 43

r Core - Inspect...................................... 44

Battery Cable - Disconnect ................... 46

nt ......................................................... 47

nspect/Adjust/Replace (Fan Drive Belts)... 47

ment...................................................... 48

t................................................................. 7

eather Starting ........................................... 27

Engine Air Cleaner Service Indicator - Inspect ...... 55

Service Indicator Check ..................................... 55

Service Indi

Engine Crankcase Breather - Clean...................... 56

Engine Description ................................................ 15

Engine Cool

Engine Speciﬁcations......................................... 15

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

System Desc

Engine Lifting......................................................... 19

Engine Mounts - Inspect........................................ 56

Engine Oil

Drain the Engine Lubricating Oil ........................ 59

Fill the Oil Pan.................................................... 60

Replace th

Engine Oil Filter (Auxiliary) - Change .................... 57

Change the Filter with the Engine in Operation.. 57 Engine Oi

Engine Oil Pump - Inspect ..................................... 58

Engine Oil Sample - Obtain ................................... 58

Initiat

Obtain the Sample and the Analysis.................. 58

Engine Operation................................................... 28

Engine P

Visual Inspection................................................ 61

Engine Starting ................................................ 10, 26

Engine

Engine Storage...................................................... 21

Level “A ” ........................................................... 21

Level “

Level “C ” .......................................................... 21

Engine V alve Lash - Inspect/Adjust (Valves and Valve

es) ............................................................... 61

Bridg

Fan Drive Pulley - Check....................................... 63

ures and Controls ........................................... 22

Feat

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

Fire Extinguisher .................................................. 9

s, Tubes and Hoses ...................................... 9

Line Fluid Recommendations (Cooling System

Speciﬁcations) ..................................................... 30

Cooling System Maintenance .................... 32

ELC

General Coolant Information.............................. 30

Fluid Recommendations (Fuel Speciﬁcations) ...... 35

l Recommendations ..................................... 35

Fue Fluid Recommendations (General Lubricant

Information).......................................................... 38

ne Oil ............................................

cator Reset...................................... 56

ing and Lubrication ......................... 16

ription ............................................. 11

and Filter - Change .............................. 59

e Oil Filter ......................................... 59

l Level - Check ....................................... 57

ing an Oil analysis Program ...................... 58

rotective Devices - Check ....................... 60

Stopping .............................................. 10, 29

B ” ........................................................... 21

.............. 38

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

ergency Stopping ............................................. 29

Emissions Warranty Information............................ 76

Engine - Clean....................................................... 54

ngine Air Cleaner Element - Replace.................. 55

Page 78

78 SEBU8604 Index Section

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

California Proposition 65 Warning ....................... 4

Literature Information........................................... 4

Maintenance ........................................................ 4

Maintenance Intervals.......................................... 4

Operation ............................................................. 4

Overhaul .............................................................. 4

Safety................................................................... 4

Fuel Conservation Practices.................................. 28

Fuel Inject

Inspect the Fuel Injectors................................... 64

Fuel System - Prime .............................................. 64

Fuel System

Fuel Filter with Water Separator ........................ 65

Fuel System Primary Filter/Water Separator -

Drain .................................................................... 66

Fuel Tank Water and Sediment - Drain ................. 66

Drain the Water and the Sediment..................... 66

Fuel Stora

Fuel Tank ........................................................... 66

Fuel Transfer Pump (Lift Pump) - Inspect ............. 67

Replacem

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

Contain

Fluid Penetration.................................................. 6

Pressure Air and Water........................................ 6

General

Governor Actuator - Check .................................... 68

Hoses

Replace the Hoses and the Clamps .................. 68

Impo

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

Maintenance Interval Schedule ............................. 42

Maintenance Section ............................................. 30

del View Illustrations ......................................... 13

4016-61TRG ...................................................... 13

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

nitoring System................................................. 22

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

or - Inspect/Adjust ................................. 64

Filter - Replace ................................. 65

ge Tanks............................................ 67

ent of the Lift Pump............................ 67

ing Fluid Spillage ..................................... 6

Information............................................... 12

and Clamps - Inspect/Replace ................... 68

rtant Safety Information ................................... 2

Operation Section.................................................. 19

Overhaul (Maj

Major Overhaul Information ............................... 69

Scheduling a Major Overhaul............................. 69

Overhaul (To

Scheduling a Top End Overhaul ........................ 69

Top End Overhaul Information ........................... 70

Plate Locations and Film Locations....................... 17

Engine Identiﬁcation........................................... 17

Serial Num

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

Product Information Section .................................. 12

Radiator - Clean .................................................... 70

Reﬁll Capacities..................................................... 30

Cooling S

Fuel System ....................................................... 30

Lubrication System ............................................ 30

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

(1) Universal Warning .......................................... 5

(2) Hot

Safety Section ......................................................... 5

Sensors and Electrical Components ..................... 22

Boost

Coolant Temperature Sensor ............................. 23

Engine Oil Pressure Switch ............................... 24

High T

Sensor.............................................................. 24

Overspeed Sensor ............................................. 25

Sens

Speed Sensor .................................................... 25

Severe Service Application - Check ...................... 71

ronmental Factors ....................................... 71

Envi

Incorrect Maintenance Procedures .................... 71

Incorrect Operating Procedures ......................... 71

ed Sensor - Clean/Inspect (Engine Speed Sensor

Spe

and Overspeed Sensor)....................................... 72

Engine Speed Sensor ........................................ 72

rspeed Sensor ............................................. 72

Ove

Starting Motor - Inspect ......................................... 73

Starting the Engine ................................................ 26

rmal Engine Starting Procedure .................... 26

Stopping the Engine .............................................. 29

or).................................................... 69

p End) ............................................... 69

ber Plate........................................... 18

ystem.................................................. 30

Coolant..................................................... 5

Pressure Sensors ............................ ........ 23

urbine Inlet Temperature Shutdown

or Locations ............................................... 22

able of Contents..................................................... 3

Page 79

SEBU8604 79

Index Section

Turbocharger -

Walk-Around Inspection ........................................ 74

Warranty Inf

Warranty Section ................................................... 76

Water Pump - Inspect............................................ 75

Welding on E

Inspect .......................................... 74

ormation ............................................. 76

ngines with Electronic Controls ........ 12

Page 80

80 SEBU8604 Index Section

Page 81

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 82