Perkins Engine 402D, 403D, 404D Service Manual

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Page 1

Operation and

This document has been printed from SPI². Not for Resale

Maintenance Manual

SEBU8311-01

April 2008

402D-403D-404D Industrial Engine

(Engine)

GG GH

(Engine)

GJ GK

(Engine)

GM GN

(Engine)

GP GQ

(Engine)

Page 2

Important Safety Information

This document has been printed from SPI². Not for Resale

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

SEBU8311-01 3

This document has been printed from SPI². Not for Resale

Table of Contents

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

Safety Section

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

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

Burn Prevention ...................................................... 8

Fire Prevention and Explosion Prevention .............. 8

Crushing Prevention and Cutting Prevention ........ 10

Before Starting Engine ........................................... 11

Engine Starting ...................................................... 11

Engine Stopping .................................................... 11

Electrical System .................................................. 12

Product Information Section

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

Product Identiﬁcation Information ........................ 23

Operation Section

Lifting and Storage ................................................ 25

Gauges and Indicators .......................................... 28

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

Engine Starting ..................................................... 30

Engine Operation .................................................. 33

Engine Stopping ................................................... 34

Cold Weather Operation ....................................... 35

Maintenance Section

Reﬁll Capacities .................................................... 39

Maintenance Interval Schedule ............................ 58

Warranty Section

Warranty Information ............................................ 89

Index Section

Index ..................................................................... 90

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4 SEBU8311-01

This document has been printed from SPI². Not for Resale

Foreword

Literature Information

This manual con lubrication and maintenance information. This manual should be stored in or near the engine area in a literatur 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 consiste

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

Safety

This safety section lists basic safety precautions. In addition, this section identiﬁes hazardous, warning si precautions listed in the safety section before operating or performing lubrication, maintenance and repair on

this product.

tains safety, operation instructions,

e holder or literature storage area. Read,

ncy.

or attachments that may be different

t and advancement of product design

arding your engine, or this manual, please

tuations. Read and understand the basic

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 mini avoidances resulting from reductions in unscheduled downtime and failures.

ive maintenance program is followed, a

mize 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 maintenan near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of

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

ce schedules be reproduced and displayed

the engine’s permanent record.

tor can assist you in adjusting your

Overhaul

Operatio

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

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

ey assist with developing the skills and

as the operator gains knowledge of the

ation section is a reference for operators.

pping the engine. This section also includes a

Maintenance

The mai The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance interv referenced to detailed instructions that follow.

ntenance section is a guide to engine care.

als. Items in the maintenance schedule are

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the i interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your P regarding overhaul programs. If you experience a major engine failure, there are also numerous after f your Perkins dealer or your Perkins distributor for information regarding these options.

nterval and the maintenance items in that

erkins distributor offers a variety of options

ailure overhaul options available. Consult with

California Proposition 65 Warning

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

defects, and other reproductive harm. Battery

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

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SEBU8311-01 5

This document has been printed from SPI². Not for Resale

Safety Section

Safety Messages

Safety Section

i02959960

Safety Message s

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

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

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

everal speciﬁc warning signs on your

iar with all warning signs.

igns or replace the warning signs if

signs. Do not use solvents, gasoline, or

gns. The warning signs that are loosened

y warning sign that is damaged or

ement part. Your Perkins dealer or your

Warning label ( The location will change according to the physical size of the engine.

A) is installed in different locations.

(A) Universal Warning

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

Illustration 1

lexample

Typica

ead and understand the instructions

warnings could result in serious injury

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Safety Section Safety Messages

Illustration 2

(A) Location of warning label (1) 402D-05 (2) 403D-07

(3) 403D-11 (4) 403D-15, 403D-15T and 403D-17 (5) 404D-15

(6) 404D-22, 404D-22T and 404D-22TA

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This document has been printed from SPI². Not for Resale

Safety Section

General Hazard Information

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 s repair the equipment.

ervice the equipment or before you

g00104545

Report all nece

Do not allow unauthorized personnel on the equipment.

Ensure that the power supply is disconnected before youworkonthe

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

ssary repairs.

bus bar or the glow plugs.

he servicing position. Refer to the

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 inj

The direct application of pressurized air or pressurize injury.

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

ury.

d water to the body could result in personal

rized air and/or water is used for

ivefaceshield.

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 walkway

s, and from steps.

g0070202

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

w 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 hyd escape rapidly if the pressure is not relieved correctly.

Do not rem 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

raulic ﬂuid or items such as pipe plugs to

ove any hydraulic components or parts

ts or parts until pressure has been relieved

the hydraulic pressure.

Never put maintenance ﬂuids into glass containers. Drain al

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

l liquids into a suitable container.

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Safety Section Burn Prevention

Coolant

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

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

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

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 ﬂuidwitha 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.

Only use the tools that are suitable for containing

•

ﬂuids and equipment that is suitable for containing ﬂuids.

Obey all local regulations for the disposal of liquids.

Ensure that the ﬁller cap is cool before removing the ﬁller cap. The ﬁller cap must be cool enough to touch with a bare hand. Remove the ﬁller cap slowly in order to relieve pressure.

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

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.

i028134

Fire Prevention an d Explosion Prevent

ion

i02143195

Burn Pre

Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is perfo in the air system, in the hydraulic system, in the lubrication system, in the fuel system, or in the coolin items are disconnected.

rmed on the engine. Relieve all pressure

g system before any lines, ﬁttings or related

vention

Illust

ration 6

g00704000

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SEBU8311-01 9

This document has been printed from SPI². Not for Resale

Safety Section

Fire Prevention and Explosion Prevention

All fuels, most are ﬂammable.

Flammable ﬂui surfaces or onto electrical components can cause a ﬁre. Fire may cause personal injury and property damage.

A ﬂash ﬁre may result if the covers for the engine crankcase ar an emergency shutdown.

Determine wh environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the eng property damage, or engine damage could result.

If the appli gases, consult your Perkins dealer and/or your Perkins distributor for additional information about suitable p

Remove all ﬂammable combustible materials or conductiv the engine. Do not allow any ﬂammable combustible materials or conductive materials to accumulate on the engine

lubricants, and some coolant mixtures

ds that are leaking or spilled onto hot

e removed within ﬁfteen minutes after

ether the engine will be operated in an

ine to overspeed. Personal injury,

cation involves the presence of combustible

rotection devices.

e materials such as fuel, oil, and debris from

Arcing or spark connections, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking.

Inspect all lines and hoses for wear or for deteriorati The lines and hoses must have adequate support and secure clamps. Tighten all connections to the recommended

Oil ﬁlters and fuel The ﬁlter hou torque.

ing could cause a ﬁre. Secure

on. The hoses must be correctly routed.

torque. Leaks can cause ﬁres.

ﬁlters must be correctly installed.

sings must be tightened to the correct

Store fuels and lubricants in correctly marked container oily rags and any ﬂammable materials in protective containers. Do not smoke in areas that are used for storing ﬂ

Do not expose the engine to any ﬂame.

Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a tube, or installed correctly.

Do not we

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

thoroug welding or ﬂame cutting.

Wiring m wires must be correctly routed and securely attached. Check all electrical wires daily. Repair any wires that ar engine. Clean all electrical connections and tighten all electrical connections.

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

s away from unauthorized persons. Store

ammable materials.

a seal failure. Exhaust shields must be

ld on lines or tanks that contain ﬂammable

hly with a nonﬂammable solvent prior to

ust be kept in good condition. All electrical

e loose or frayed before you operate the

ommended gauge. Do not bypass any fuses

Illustration 7

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

g00704059

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10 SEBU8311-01

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Safety Section Crushing Prevention and Cutting Prevention

Illustration 8

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.

g00704135

Repair any line can cause ﬁres. Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts.

Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to to the recommended torque.

Replace the p are present:

End ﬁttings a

•

Outer coverings are chafed or cut.

•

Wires are exposed.

•

Outer coveri

•

Flexible part of the hoses are kinked.

•

Outer covers have embedded armoring.

•

End ﬁttings a

•

Make sure that all clamps, guards, and heat shields are installe will help to prevent vibration, rubbing against other parts, and excessive heat.

s that are loose or damaged. Leaks

check for leaks. Tighten all connections

arts if any of the following conditions

re damaged or leaking.

ngs are ballooning.

re displaced.

d correctly. During engine operation, this

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

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

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

Fire Extinguisher

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

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. Do not clip any other items to the high pressure lines.

i02143194

Crushing Prevention and Cutting Prevention

Support th the component is performed.

Unless oth never attempt adjustments while the engine is running.

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

Keep obje blades will throw objects or cut objects.

When obje order to avoid injury to the eyes.

Chips or o are struck. Before objects are struck, ensure that no one will be injured by ﬂying debris.

e component correctly when work beneath

er maintenance instructions are provided,

med. After the maintenance is performed,

cts away from moving fan blades. The fan

cts are struck, wear protective glasses in

ther debris may ﬂy off objects when objects

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Safety Section

Before Starting Engine

i02813489

Before Starting Engine

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

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

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 free

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

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

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

See the Se adjustments.

ial start-up of an engine that is new,

ed by shutting off the air and/or fuel

tdown should occur automatically for

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

of personnel.

itable for the conditions. Ensure that all

ive guards and all protective covers must

hat is caused by parts in rotation, work

ss the automatic shutoff circuits. Do not

are also provided in order to help prevent

rvice Manual for repairs and for

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

Start the eng from the engine start switch.

Always start that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Kno 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) and/or the l correctly, check the water temperature gauge and the oil temperature gauge during the heater operation.

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

Note: The engine is equipped with an automatic device for cold starting for normal conditions of operatio conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the corre operation.

The 400 S plug starting aid in each individual cylinder that heats the intake air in order to improve starting.

guards and all protective covers must

is caused by parts in rotation, work

ine from the operator’s compartment or

theengineaccordingtotheprocedure

wing the correct procedure will help to

jury.

ube oil heater (if equipped) is working

operate the engine in a well ventilated

n. If the engine will be operated in very cold

ct type of starting aid for your region of

eries engines are equipped with a glow

i02590389

i02157354

Engine Starting

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

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

Engine St opp ing

To avoid overheating of the engine and accelerated wear of the engine components, stop the engine according to this Operation and Maintenance Manual, “Engine Stopping” topic (Operation Section).

Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. DO N OT 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.

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12 SEBU8311-01

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Safety Section Electrical System

On the initial s that has been serviced, make provisions to stop the engine if an overspeed condition occurs. This may be accomplished the air supply to the engine.

If equipped, controlled engine, cut the power to the engine.

tart-up of a new engine or an engine

by shutting off the fuel supply and/or

in order to stop an electronically

i02176668

Electrical System

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

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

Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for speciﬁc starting instructions.

Grounding Practices

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

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

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

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

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

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Product Information Section

Model Views

Product Information Section

Model Views

i02590436

Model View Illustrations

The following model views show typical features of the 400 series engines. Due to individual applications, your engine may appear different from the illustrations.

Note: Individual components are detailed on the 404D-22T turbocharged engine only.

Illustration 9

Typical view of the 402D-05 engine

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Product Information Section Model Views

Illustration 10

Typical view of the 403D-15 T engine

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SEBU8311-01 15

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Product Information Section

Model Views

Illustration 11

Front and right side view of the 404D-22T Engine

(1) Fuel shutoff solenoid (2) Number one fuel injector (3) Water pump (4) Lower engine oil ﬁller cap

(5) Throttle lever (6) Cover plate for the a ccessory drive (7) Engine oil level gauge (8) Engine oil coo ler

g01304893

(9) Engine oil ﬁlter (10) Fuel injection pump (11) Transfer pump (12) Fuel ﬁlter

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Product Information Section Model Views

Illustration 12

Front and left side view of the 404D-22T Engine

(13) Top engine oil ﬁller c ap (14) Crankcase breather (15) Rear Lifting eye (16) Air inlet elbow (17) Valve mechanism cover (18) Turbocharger

(19) Water temperature regulator hous ing (20) Starting motor solenoid (21) Electric starting motor (22) Alternator (23) Engine oil pan (24) Engine oil drain plug

i02959055

Engine De script ion

The 400 series engines are indirect injection engines. The engines are controlled with a mechanically actuated fuel injection pump. The engine cylinders are arranged in-line.

The cylinder head assembly has one inlet valve and one exhaust valve for each cylinder. Each cylinder valve has a single valve spring.

g01305224

(25) Fan drive belt (26) Crankshaft pulley (27) Coolant tem perature switch (28) Cooling fan

The pistons have two compression rings and an oil control ring. It is important to ensure the correct piston height so that the piston does not contact the cylinder head. The correct piston height also ensures efﬁcient combustion of fuel that is necessary in order to conform to requirements for emissions.

The crankshaft for a two cylinder engine has two main bearing journals. The crankshaft for a three cylinder engine has four main bearing journals. The crankshaft for a four cylinder engine has ﬁve main bearing journals. End play is controlled by the thrust washers that are located on the rear main bearing.

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Product Information Section

Model Views

The timing gear order to ensure the correct assembly of the gears. WhentheNo.1pistonisattopcentercompression stroke, the te gear and the camshaft gear will be in alignment with the idler gear.

The crankshaft gear turns the idler gear which then turns the camshaft gear and the gear for the engine oil pump.

The fuel injection pump is mounted in the cylinder block. The fu on the camshaft. The fuel transfer pump is located on the right hand side of the cylinder block. The fuel transf camshaft.

The fuel inj for emissions. If any adjustments to the fuel injection pumptimingandhighidlearerequiredyoumust refer to yo dealer. Some fuel injection pumps have mechanical governors that control the engine rpm. Some fuel injection controlled.

s are stamped with timing marks in

eth that are stamped on the crankshaft

el injection pump is operated by lobes

er pump is also operated by lobes on the

ection pump conforms to requirements

ur Perkins distributoror your Perkins

pumps have a governor that is electrically

Engine Speciﬁcations

Note: The front end of the engine is opposite the

ﬂywheel end of the engine. The left and the right side of the engine are determined from the ﬂywheel end. The No. 1 cylinder is the front cylinder.

A gerotor gear. The engine oil pump sends lubricating oil to the main oil gallery through a pressure relief valve and an engine oi oil through an externally located oil line that runs from the main oil gallery to the cylinder head.

Coolant from the bottom of the radiator passes through the belt driven centrifugal water pump. The coolant is regulated by a water temperature regulator.

Engine e engine performance depend on adherence to correct operation and maintenance recommendations. Engine the use of recommended fuels, lubrication oils, and coolants. Refer to the Operation and Maintenance Manual information on maintenance items.

oil pump is located in the center of the idler

l ﬁlter. The rocker arms receive pressurized

is cooled by the radiator and the temperature

fﬁciency, efﬁciency of emission controls, and

performance and efﬁciency also depend on

, “Maintenance Interval Schedule” for more

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Product Information Section Model Views

402D-05 Engine

Illustratio

(A) Ex haust valves (B) I nlet valves

Table 1

n13

402D-05 Engine Speciﬁcations

Maximum Operating Speed (rpm)

Cylinders and Arrangement

Bore

3600 rpm

In-Line two cylinder

67 mm (2.64 inch)

Stroke 72 mm (2.83 inch)

Displacement 0.507 L (30.939 in3)

Aspiration NA

Compression Ratio

Firing Order

Rotation that is viewed from the ﬂy

wheel

23.5:1

1-2

Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1)

Naturally Aspirated

g01108476

(1)

403D-07 Engine

Illustratio

(A) Exhaus t valves (B) Inlet valves

Table 2

n14

403D-07 Engine Speciﬁcations

Maximum Operating Speed (rpm)

Cylinders and Arrangement

Bore

3600 rpm

In-Line three cylinder

67 mm (2.64 inch)

Stroke 72 mm (2.83 inch)

Displacement 0.762 L (46.500 in3)

Aspiration NA

Compression Ratio

Firing Order

Rotation that is viewed from the ﬂy

wheel

23.5:1

1-2-3

Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1)

Naturally A spirat ed

g00852304

(1)

Page 19

SEBU8311-01 19

This document has been printed from SPI². Not for Resale

Product Information Section

Model Views

403D-11 Engine

Illustratio

(A) Ex haust valves (B) I nlet valves

Table 3

n15

403D-11 Engine Speciﬁcations

Maximum Operating Speed (rpm)

Cylinders and Arrangement

Bore

3600 rpm

In-Line three cylinder

77 mm (3.03 inch)

Stroke 81 mm (3.19 inch)

Displacement 1.131 L (69.018 in3)

Aspiration NA

Compression Ratio

Firing Order

Rotation that is viewed from the ﬂy

wheel

23:1

1-2-3

Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1)

Naturally Aspirated

g00852304

(1)

403D-15 Engine

Illustratio

(A) Exhaus t valves (B) Inlet valves

Table 4

n16

403D-15 Engine Speciﬁcations

Maximum Operating Speed (rpm)

Cylinders and Arrangement

Bore

3000 rpm

In-Line three cylinder

84 mm (3.31 inch)

Stroke 90 mm (3.54 inch)

Displacement 1.496 L (91.291 in3)

Aspiration NA

Compression Ratio

Firing Order

Rotation that is viewed from the ﬂy

wheel

22.5:1

1-2-3

Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1)

Naturally A spirat ed

g00852304

(1)

Page 20

20 SEBU8311-01

This document has been printed from SPI². Not for Resale

Product Information Section Model Views

403D-15T Engin

Illustratio

(A) Ex haust valves (B) I nlet valves

Table 5

n17

g00852304

403D-15T Engine Speciﬁcations

Maximum Operating Speed (rpm)

Cylinders and Arrangement

Bore

3000 rpm

In-Line three cylinder

84 mm (3.31 inch)

Stroke 90 mm (3.54 inch)

Displacement 1.496 L (91.291 in3)

Aspiration T

Compression Ratio

Firing Order

Rotation that is viewed from the ﬂy

wheel

Counterclockwise

(1)

22.5:1

1-2-3

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1)

Turbocharged

403D-17 Engine

Illustratio

(A) Exhaus t valves (B) Inlet valves

Table 6

n18

403D-17 Engine Speciﬁcations

Maximum Operating Speed (rpm)

Cylinders and Arrangement

Bore

2600 rpm

In-Line three cylinder

84 mm (3.31 inch)

Stroke 100 mm (3.94 inch)

Displacement 1.66 L (101.3 in3)

Aspiration NA

Compression Ratio

Firing Order

Rotation that is viewed from the ﬂy

wheel

23.1:1

1-2-3

Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1)

Naturally A spirat ed

g00852304

(1)

Page 21

SEBU8311-01 21

This document has been printed from SPI². Not for Resale

Product Information Section

Model Views

404D-15 Engine

Illustratio

(A) Ex haust valves (B) I nlet valves

Table 7

n19

404D-15 Engine Speciﬁcations

Maximum Operating Speed (rpm)

Cylinders and Arrangement

Bore

3000 rpm

In-Line four cylinder

77 mm (3.03 inch)

Stroke 81 mm (3.19 inch)

Displacement 1.508 L (92.024 in3)

Aspiration NA

Compression Ratio

Firing Order

Rotation that is viewed from the ﬂy

wheel

23.5:1

1-3-4-2

Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1)

Naturally Aspirated

g00296424

(1)

404D-22 Engine

Illustratio

(A) Exhaus t valves (B) Inlet valves

Table 8

n20

404D-22 Engine Speciﬁcations

Maximum Operating Speed (rpm)

Cylinders and Arrangement

Bore

3000 rpm

In-Line four cylinder

84.0 mm (3.31 inch)

Stroke 100.0 m m (3.94 inch)

Displacement 2.216 L (135.229 in3)

Aspiration NA

Compression Ratio

Firing Order

Rotation that is viewed from the ﬂy

wheel

23.3:1

1-3-4-2

Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1)

Naturally A spirat ed

g00296424

(1)

Page 22

22 SEBU8311-01

This document has been printed from SPI². Not for Resale

Product Information Section Model Views

404D-22T Engin

Illustratio

(A) Ex haust valves (B) I nlet valves

Table 9

n21

g00296424

404D-22T Engine Speciﬁcations

Maximum Operating Speed (rpm)

Cylinders and Arrangement

Bore

3000 rpm

In-Line four cylinder

84.0 mm (3.31 inch)

Stroke 100.0 mm (3.94 inch)

Displacement 2.216 L (135.229 in3)

Aspiration T

Compression Ratio

Firing Order

Rotation that is viewed from the ﬂy

wheel

Counterclockwise

(1)

23.5:1

1-3-4-2

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1)

Turbocharged

404D-22TA Engi

Illustratio

(A) Exhaus t valves (B) Inlet valves

Table 10

n22

g00296424

404D-22TA Engine Speciﬁcations

Maximum Operating Speed (rpm)

Cylinders and Arrangement

Bore

2800 rpm

In-Line four cylinder

84.0 mm (3.31 inch)

Stroke 100.0 m m (3.94 inch)

Displacement 2.216 L (135.229 in3)

Aspiration TA

Compression Ratio

Firing Order

Rotation that is viewed from the ﬂy

wheel

Counterclockwise

(1)

23.5:1

1-3-4-2

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1)

Turbocharged aftercooled

Page 23

SEBU8311-01 23

This document has been printed from SPI². Not for Resale

Product Information Section

Product Identiﬁcation Information

i02643641

Engine Identiﬁcation

Perkins engines are identiﬁed by a serial number. This number is shown on a serial number plate that is mounted above the fuel injection pump on the right hand side of the engine block.

An example of an engine number is GP*****U000001M.

________________________________ _________Type of engine

____________________________ Built in the United Kingdom

______________________ The list number of the engine

*****

000001

___________________________ Engine Serial Number

The following i Number Plate: Engine serial number, Model, and Arrangement number.

nformation is stamped on the Serial

i02164876

Reference Numbers

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

Record for Reference

Engine Model _ ______________________________________________

Engine Serial number _____________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

____________________________________ Year of Manufacture

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

i02157258

Serial Number Plate

Primary Fuel Filter _________________________________________

Water Separator Element ________________________________

Secondary Fuel Filter Element __________________________

Lubrication Oil Filter Element ___________________________

Auxiliary Oil Filter Element _______________________________

Total Lubrication System Capacity ______ _______________

Total Cooling System Capacity _________________________

Air Cleaner Element _______________________________________

Fan Drive Belt ______________________________________________

Alternator Belt ______________________________________________

tion 23

Illustra

Typical serial number plate

The Serial Number Plate is located above the fuel injection pump on the right side of the cylinder block.

g01094203

Page 24

24 SEBU8311-01

This document has been printed from SPI². Not for Resale

Product Information Section Product Identiﬁcation Information

i02959144

Emissions Certiﬁcation Film

Illustration 24

Typical exam p le

Illustration 25

Typical exam p le

g01478138

g01476654

Perkins Shibaura Engines Limited will supply the fuel label with every engine. Refer to illustration

25. The equipment manufacturer must install the label to the equipment. This is recommended by Perkins Shibaura Engines Limited. The label must be attached to the equipment near the fuel inlet. This will comply with the EPA regulations. The equipment manufacturer may install another fuel label. If another fuel label is used, the equipment manufacturer must send a drawing or a photo of the label to Perkins Shibaura Engines Limited through the Perkins Distributor. This will ensure compliance of the label.

Page 25

SEBU8311-01 25

This document has been printed from SPI². Not for Resale

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

Engine Lifting

i02164186

Some removals r obtain correct balance and safety.

To r em ov e t h e e are on the engine.

Lifting eyes a engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting ﬁxtures obso that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information lifting.

equire lifting the ﬁxtures in order to

ngine ONLY, use the lifting eyes that

re designed and installed for speciﬁc

lete. If alterations are made, ensure

regarding ﬁxtures for correct engine

i02593735

Engine Storage

If the engine will not be started for several weeks, the lubricating oil will drain from the cylinder walls and from the piston rings. Rust can form on the cylinder walls. Rust on the cylinder walls will cause increased engine wear and a reduction in engine service life.

Illustration 26

NOTICE Never bend the eyebolts and the brackets. Only load the eyeb ber that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes le

When it is necessary to remove a component at an angle, o the weight.

Use a ho an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parall be perpendicular to the top of the object that is being lifted.

olts and the brackets under tension. Remem-

ss than 90 degrees.

nly use a link bracket that is properly rated for

ist to remove heavy components. Use

el to each other. The chains and cables should

g01097527

Lubrication System

To help prevent excessive engine wear, use the following guidelines:

Complete all of the lubrication recommendations that are listed in this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section).

If an engine is out of operation and if use of the engine is not planned, special precautions should be made. If the engine will be stored for more than one month, a complete protection procedure is recommended.

Use the following guidelines :

Completely clean the outside of the engine.

•

Drain the fuel system completely and reﬁll

•

thesystemwithpreservativefuel.1772204 POWERPART Lay-Up 1 can be mixed with the normal fuel in order to change the fuel into preservative fuel.

If preservative fuel is not available, the fuel system

•

can be ﬁlled with normal fuel. This fuel must be discarded at the end of the storage period together with the fuel ﬁlter elements.

Operate the engine until the engine reaches normal

•

operating temperature. Stop any leaks from fuel, lubricating oil or air systems. Stop the engine and drain the lubricating oil from the oil pan.

Page 26

26 SEBU8311-01

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Operation Section Lifting and Storage

Renew the canis

•

FilltheoilpantotheFullMarkontheengineoil

•

level gauge wi 1762811 POWERPART Lay-Up 2 to the oil in order to protect the engine against corrosion. If 1762811 POWE use a preservative of the correct speciﬁcation instead of the lubricating oil. If a preservative is used, this mu the storage period and the oil pan must be reﬁlled to the correct level with normal lubricating oil.

ter(s) of the lubricating oil ﬁlter.

th new, clean lubricating oil. Add

RPART Lay-Up 2 is not available,

st be drained completely at the end of

Cooling System

To help prevent excessive engine wear, use the following guidelines:

NOTICE Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can

If freezing temperatures are expected, check the cooling sys freezing. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” (Maintenance Section).

To prevent frost damage, ensure that all the coolant is removed fr tem is drained after it has been ﬂushed with water, or if an antifreeze solution too weak to protect the system from frost

be discharged.

tem for adequate protection against

NOTICE

om the engine. This is important if the sys-

has been used.

1. Ensure that the

2. Remove the ﬁller cap of the cooling system.

3. Remove the drain plug (1) from the side of the

cylinder block in order to drain the engine. Ensure that the drain

4. Open the tap or remove the drain plug at the bottom of the r If the radiator does not have a tap or a drain plug, disconnect the hose at the bottom of the radiator.

5. Flushthecoolingsystemwithcleanwater.

6. Fit the drain

or connect the radiator hose.

7. Fill the cool mixture because this gives protection against corrosion.

Note: Certain corrosion inhibitors could cause damage to some engine components. Contact the Service Dep

8. Operate the engine for a short period in order to circulate t engine.

9. Disconnect storage in a fully charged condition. Before the battery is put into storage, protect the terminals against co Lay-Up 3 can be used on the terminals.

10. Clean the c Seal the end of the pipe.

vehicle is on level ground.

hole is not restricted.

adiator in order to drain the radiator.

plugs and the ﬁller cap. Close the tap

ing system with an approved antifreeze

artment of Perkins for advice.

he lubricating oil and the coolant in the

the battery. Put the battery into safe

rrosion. 1734115 POWERPART

rankcase breather if one is installed.

11. Remove the POWERPART Lay-Up 2 for one or two seconds into each cylinder bore with the piston at BDC.

12. Slowly rotate the crankshaft for one complete revolution and then replace the fuel injectors.

fuel injectors and spray 1762811

Induction System

Remove the air ﬁlter assembly. If necessary,

•

remove the pipes that are installed between

ter assembly and the turbocharger.

ntainer. Seal the turbocharger with

Illustration 27

Typical exam p le

the air ﬁl Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spray is printed on the co waterproof tape.

g01298045

Page 27

SEBU8311-01 27

This document has been printed from SPI². Not for Resale

Operation Section

Lifting and Storage

Exhaust System

Remove the exhaust pipe. Spray 1762811

•

POWERPART Lay-Up 2 into the turbocharger. The duration of the spray is printed on the container. Seal the turbocharger with waterproof tape.

General Items

If the lubricating oil ﬁller is installed on the valve

•

mechanism cover, remove the ﬁller cap. If the lubricating oil ﬁller cap is not installed on the valve mechanism cover, remove the valve mechanism cover. Spray 1762811 POWERPART Lay-Up 2 around the rocker shaft assembly. Replace the ﬁller cap or the valve mechanism cover.

Seal the vent of the fuel tank or the fuel ﬁller cap

•

with waterproof tape.

Remove the alternator drive belts and put the drive

•

belts into storage.

In order to prevent corrosion, spray the engine with

•

1734115 POWERPART Lay-Up 3. Do not spray the area inside the alternator.

When the engine protection has been completed in accordance with these instructions, this ensures that no corrosion will occur. Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.

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

Page 28

28 SEBU8311-01

This document has been printed from SPI². Not for Resale

Operation Section Gauges and Indicators

Gauges and Ind icators

i02216960

Gauges and Indicators

Your engine m the gauges that are described. For more information about the gauge package, see the OEM information.

Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine th the gauges over a period of time.

Noticeable c potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the r Determine and correct the cause of any signiﬁcant change in the readings. Consult your Perkins dealer or your Per

If no oil pressure is indicated, STOP the engine. If maximum co the engine. Engine damage can result.

SAE10W30 rpm.

ay not have the same gauges or all of

e normal operating range by observing

hanges in gauge readings indicate

eadings are within speciﬁcations.

kins distributor for assistance.

NOTICE

olant temperature is exceeded, STOP

Engine Oil

should be greatest after a cold engine is started. The typical engine oil pressure with

is 207 to 413 kPa (30 to 60 psi) at rated

Pressure – The oil pressure

1. Reduce the load

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut down

immediately or if the engine can be cooled by reducing the l

Tachometer – This gauge indicates engine speed (rpm). W

ismovedtothefullthrottlepositionwithout load, the engine is running at high idle. The engine is running at th lever is at the full throttle position with maximum rated load.

To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. The engine can be operated at high idle without damage, but should never be allowedtoexceedhighidlerpm.

indicator should be to the right side of “0” (zero).

is in the “ON” position.

efullloadrpmwhenthethrottlecontrol

Ammeter – This gauge indicates the

amount of charge or discharge in the

battery charging circuit. Operation of the

Fuel Level – This gauge indicates the fuel

level in the fuel tank. The fuel level gauge

operates when the “START/ST OP” switch

Service Hour Meter – The gauge indicates

operating time of the engine.

and the engine rpm.

oad.

hen the throttle control lever

NOTICE

A lower oil pressure is normal at low idle. If the load is stable the following procedure:

1. Remove th

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

tempera at 90 kPa (13 psi) is 110°C (230°F). Higher temperatures may occur under certain conditions. The wate to load. The reading should never exceed the boiling point for the pressurized system that is being used.

If the en and steam becomes apparent, perform the following procedure:

and the gauge reading changes, perform

e load.

Jacket Wa

Typical temperature range is 71 to 96°C (160 to 205°F). The maximum allowable

ture with t he pressurized cooling system

r temperature reading may vary according

gine is operating above the normal range

ter Coolant Temperature –

Page 29

SEBU8311-01 29

This document has been printed from SPI². Not for Resale

Operation Section

Features and Controls

i02593769

Fuel Shutoff

The fuel shutoff solenoid is located on the fuel injection pump. When the fuel shutoff solenoid is activated, the solenoid moves the fuel rack to the “OFF” position.

Illustration 28

(1) Fuel shutoff solenoid

If an electronically controlled governor has been installed the governor operates the fuel rack in order to stop the engine.

g01305771

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30 SEBU8311-01

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Operation Section Engine Starting

Engine Starting

i02194223

Before Starting Engine

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

For the maxim

•

thorough inspection within the engine compartment before the engine is started. Look for the following items: oil l excessive dirt and/or grease. Remove any excess dirt and/or grease buildup. Repair any faults that were ident

Inspect the cooling system hoses for cracks and

•

for loose c

Inspect the alternator and accessory drive belts for

•

cracks, br

Inspect the wiring for loose connections and for

•

worn wires

Check the fuel supply. Drain water from the water

•

separator (if equipped).

All valve and during engine operation to help prevent high fuel pressure. High fuel pressure may cause ﬁlter housing failure o

gine is started, perform the required

nce Manual, “Maintenance Interval

um service life of the engine, make a

eaks, coolant leaks, loose bolts, and

iﬁed during the inspection.

lamps.

eaks, and other damage.

or frayed wires.

(if equipped). Open the fuel supply valve

NOTICE

s in the fuel return line must be open before

r other damage.

Do not start the

•

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

Ensure that the areas around the rotating parts are

•

clear.

All of the guards must be put in place. Check for

•

damaged guar any damaged guards. Replace damaged guards and/or missing guards.

Disconnect any battery chargers that are not

•

protected against the high current drain that is created wh engaged. Check electrical cables and check the battery for poor connections and for corrosion.

Reset all of the shutoffs or alarm components (if

•

equipped).

Check the engine lubrication oil level. Maintain the

•

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

Check the coolant level. Observe the coolant level

•

in the head coolant level to the “FULL” mark on the header tank.

If the engine is not equipped with a header tank

•

maintain the coolant level within 13 mm (0.5 inch) of the bott equipped with a sight glass, maintain the coolant level in the sight glass.

Observe the air cleaner service indicator (if

•

equipped). Service the air cleaner when the yellow diaphrag piston locks in the visible position.

m enters the red zone, or when the red

engine or move any of the controls

ds or for missing guards. Repair

en the electric starting motor is

engine oil level gauge.

er tank (if equipped). Maintain the

om of the ﬁller pipe. If the engine is

If the engine has not been started for several weeks, fuel may h may have entered the ﬁlter housing. Also, when fuel ﬁlters have been changed, some air pockets will be trapped fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information on primi

Engine exhaust contains products of combustion which may be harmful to your health. Always start and ope and, if in an enclosed area, vent the exhaust to the outside.

ave drained from the fuel system. Air

in the engine. In these instances, prime the

ng the fuel system.

rate the engi ne in a well ventilated area

Ensure t

•

engine has been disengaged from the engine. Minimize electrical loads or remove any electrical loads.

Startin

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

hat any equipment that is driven by the

g the Engine

i02665533

Page 31

SEBU8311-01 31

This document has been printed from SPI². Not for Resale

Operation Section

Engine Starting

Refer to the OEM Use the following procedure to start the engine.

1. Move the throt before you start the engine.

Do not operate onds at one time. Damage to the glow plugs could occur.

2. Turn the engin Hold the engine start switch in the HEAT position for 6 seconds until the glow plug indicator light illuminates aid in the starting of the engine.

Do not crank t Allow the electric starting motor to cool for two minutes before cranking the engine again.

3. While the glow plug indicator light is illuminated, turn the engine start switch to the START position and crank th

4. When the engine starts, release the engine start switch.

5. Slowly move the throttle lever to the low idle position an the Operation and Maintenance Manual, “After Starting Engine” topic.

Note: If the glow plug indicator light illuminates rapidly for 2 to 3 seconds, or if the glow plug indicator light fail start system. Do not use ether or other starting ﬂuids to start the engine.

s to illuminate, a malfunction exists in the cold

manual for your type of controls.

tle lever to the low idle position

NOTICE

theglowplugsformorethan60sec-

e start switch to the HEAT position.

. This will activate the glow plugs and

NOTICE

he engine for more than 30 seconds.

e engine.

dallowtheenginetoidle.Referto

i02177935

Starting with Jump Start Cables

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

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

Note: If it is possible, ﬁrst diagnose the reason

for the starting failure. Make any necessary repairs. If the engine will not start only due to the condition of the battery, either charge the battery, or start the engine with jump start cables. The condition of the battery can be rechecked after the engine has been switched OFF.

NOTICE Using a battery source with the same voltage as the electric st jump starting. The use of higher voltage will damage the electrical system.

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

When using an external electrical source to start the engine, tu “OFF” position. Turn all electrical accessories OFF before attaching the jump start cables.

arting motor. Use ONLY equal voltage for

rn the generator set control switch to the

6. If the engine does not start, release the engine start switch and allow the electric starting motor to cool. The

7. Turn the engine start switch to the OFF position in order to s

n, repeat steps 2 through step 5.

top the engine.

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

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

2. Connect one positive end of the jump start cable

gstarted.

all the en

to the pos battery. Connect the other positive end of the jump start cable to the positive cable terminal of the electri

gine’s accessories.

itive cable terminal of the discharged

cal source.

Page 32

32 SEBU8311-01

This document has been printed from SPI². Not for Resale

Operation Section Engine Starting

3. Connect one neg to the negative cable terminal of the electrical source. Connect the other negative end of the jump start cab chassis ground. This procedure helps to prevent potential sparks from igniting the combustible gases that ar

4. Start the engine.

5. Immediately after the stalled engine is started,

disconnect the jump start cables in reverse order.

After jump starting, the alternator may not be able to fully recharge batteries that are severely discharged. The batterie correct voltage with a battery charger after the engine is stopped. Many batteries which are considered unusable ar and Maintenance Manual, “Battery - Replace” and Testing and Adjusting Manual, “Battery - Test”.

s must be replaced or charged to the

e still rechargeable. Refer to Operation

ative end of the jump start cable

le to the engine block or to the

e produced by some batteries.

i01903609

After Starting Engine

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

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

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

Check for any ﬂuid or for any air leaks at idle rpm

•

and at one-half full rpm (no load on the engine) before operating the engine under load. This is not possible in some applications.

Operate the engine at low idle until all systems

•

achieve operating temperatures. Check all gauges during the warm-up period.

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

Page 33

SEBU8311-01 33

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Operation Section

Engine Operation

i02176671

Engine Operation

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

The engine ca engine reaches operating temperature. The engine will reach normal operating temperature sooner during a low power demand. This procedure is more effective than idling the engine at no load. The engine should reach operating

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

ation and maintenance are key factors

Manual are followed, costs can be

n be operated at the rated rpm after the

engine speed (rpm) and during a low

temperature in a few minutes.

ecorded frequently while the engine

data over time will also help detect

i02330149

Fuel Conservation Prac tices

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

Avoid spilling fuel.

•

Fuel expands may overﬂow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed.

Be aware of the properties of the different fuels.

•

Use only the recommended fuels.

Avoid unnecessary idling.

•

Shut off the time.

Observe the

•

Keep the air cleaner elements clean.

Maintain th

•

f the engine can affect the fuel

ons. Follow the recommended procedures

when the fuel is warmed up. The fuel

engine rather than idle for long periods of

air cleaner service indicator frequently.

e electrical systems.

One damaged battery cell will overwork the alternator. This will co

Ensure that the drive belts are correctly adjusted.

•

The drive be

Ensure that all of the connections of the hoses are

•

tight. The

Ensure that the driven equipment is in good

•

working or

Cold engines consume excess fuel. Utilize heat

•

from the j a system, when possible. Keep cooling system components clean and keep cooling system component engine without water temperature regulators. All of these items will help maintain operating temperat

nsume excess power and excess fuel.

lts should be in good condition.

connections should not leak.

der.

cket water system and the exhaust

s in good repair. Never operate the

ures.

Page 34

34 SEBU8311-01

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Operation Section Engine Stopping

Engine Stopping

i02334873

Stopping the Engine

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

Avoid accelerating the engine prior to shutting it down.

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

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

1. Remove the load from the engine. Reduce the

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

2. Stop the engine after the cool down period

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

i02176672

After Stopping Engine

Note: Before yo

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

Check the crankcase oil level. Maintain the oil level

•

between the “MIN” mark and the “MAX” mark on the engine oil

If necessary, perform minor adjustments. Repair

•

any leaks and

If the engine is equipped with a service hour meter,

•

note the read is in the Operation and Maintenance Manual, “Maintenance Interval Schedule”.

Fill the fuel tank in order to help prevent

•

accumulation of moisture in the fuel. Do not overﬁll the fuel tan

Only use antifreeze/coolant mixtures recommended in the Coolant Speciﬁcations that are in the Operation and Mainten engine damage.

Allow the en

•

u check the engine oil, do not operate

level gauge.

tighten any loose bolts.

ing. Perform the maintenance that

NOTICE

ance Manual. Failure to do so can cause

gine to cool. Check the coolant level.

i01903586

Emergency

Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.

The OEM may have equipped the application with an emergency stop button. For more information about the emergency stop button, refer to the OEM information.

Ensure that any components for the external system that support the engine operation are secured after the engine is stopped.

Stopping

NOTICE

If freezing temperatures are expected, check

•

the coolan cooling system must be protected against freezing to the lowest expected outside temperature. Add the correc

Perform all required periodic maintenance on all

•

driven equ the instructions from the OEM.

t for correct antifreeze protection. The

t coolant/water mixture, if necessary.

ipment. This maintenance is outlined in

Page 35

SEBU8311-01 35

This document has been printed from SPI². Not for Resale

Operation Section

Cold Weather Operation

i02717265

Cold Weather Operation

Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and the operation of the diesel engine is dependent on the following items:

The type of fuel that is used

•

The viscosity of the engine oil

•

The operation of the glow plugs

•

Optional Cold starting aid

•

Battery condition

•

This section will cover the following information:

Potential problems that are caused by cold weather

•

operation

Suggest steps which can be taken in order to

•

minimize starting problems and operating problems when the ambient air temperature is between 0° to−40 °C (32° to 40 °F).

Install the cor

•

before the beginning of cold weather.

Check all rubb

•

weekly.

Check all elec

•

fraying or damaged insulation.

Keep all batte

•

Fill the fuel tank at the end of each shift.

•

Check the air cleaners and the air intake daily.

•

Check the air intake more often when you operate in snow.

Ensure that the glow plugs are in working order.

•

Refer to Test

-Test”.

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

Alcohol or starting ﬂuids are h ighly ﬂammable and toxic and if improperly stored could result in injury or property

rect speciﬁcation of engine lubricant

er parts (hoses, fan drive belts, etc)

trical wiring and connections for any

ries fully charged and warm.

ing and Adjusting Manual, “Glow Plug

damage.

The operation and maintenance of an engine in freezing temperatures is complex . This is because of the following conditions:

Weather conditions

•

Engine applications

•

Recommendations from your Perkins dealer or your Perkins distributor are based on past proven practices. The information that is contained in this section provides guidelines for cold weather operation.

Hints for Cold Weather Operation

If the engine will start, operate the engine until a

•

minimum operating temperature of 81 °C (177.8 °F) is achieved. Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking.

The cooling system and the lubrication system

•

for the engine do not lose heat immediately upon shutdown. This means that an engine can be shut downforaperiodoftimeandtheenginecanstill have the ability to start readily.

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

Forjumpstartingwithcablesincoldweather,

•

refer to the Operation and Maintenance Manual, “Starting with Jump Start Cables.” for instructions.

Viscosity of the Engine Lubrication Oil

Correct engine oil viscosity is essential. Oil viscosity affects the amount of torque that is needed to crank the engine. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended viscosity of oil.

Recommendations for the Coolant

Provide cooling system protection for the lowest expected outside temperature. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended coolant mixture.

Page 36

36 SEBU8311-01

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Operation Section Cold Weather Operation

In cold weather correct glycol concentration in order to ensure adequate freeze protection.

, check the coolant often for the

Engine Block Heaters

Engine block h engine jacket water that surrounds the combustion chambers. This provides the following functions:

Startability is improved.

•

Warm up time i

•

An electric block heater can be activated once the engine is is typically a 1250/1500 W unit. Consult your Perkins dealer or your Perkins distributor for more information

Idling the E

When idling after the engine is started in cold weather, in rpm. This will warm up the engine more quickly. Maintaining an elevated low idle speed for extended periods wil throttle. The engine should not be “raced” in order to speed up the warm up process.

While the engine is idling, the application of a light load (parasitic load) will assist in achieving the minimum op operating temperature is 82 °C (179.6 °F).

eaters (if equipped) heat the

s reduced.

stopped. An effective block heater

ngine

crease the engine rpm from 1000 to 1200

l be easier with the installation of a hand

erating temperature. The minimum

Recommendations for Cool ant Warm Up

Warm up an engine that has cooled below normal operatin be performed before the engine is returned to full operation. During operation in very cold temperature conditio result from engine operation for short intervals. This can happen if the engine is started and the engine is stopped to warm up completely.

When the temperatures, fuel and oil are not completely burned in the combustion chamber. This fuel and oil causes soft ca Generally, the deposits do not cause problems and the deposits are burned off during operation at normal

When the engine is started and the engine is stopped many ti up completely, the carbon deposits become thicker. This can cause the following problems:

g temperatures due to inactivity. This should

ns, damage to engine valve mechanisms can

many times without being operated in order

engine is operated below normal operating

rbon deposits to form on the valve stems.

engine operating temperatures.

mes without being operated in order to warm

Free operation

•

Valves become stuck.

•

Pushrods may become bent.

•

Other damage t

•

result.

For this reaso the engine must be operated until the coolant temperature is 71 °C (160 °F) minimum. Carbon deposits on t and the free operation of the valves and the valve components will be maintained.

In addition, the engine must be thoroughly warmed in order to keep other engine parts in better condition and the servi extended. Lubrication will be improved. There will be less acid and less sludge in the oil. This will provide longer serv rings, and other parts. However, limit unnecessary idle time to ten minutes in order to reduce wear and unnecessa

of the valves is prevented.

o valve train components can

n, when the engine is started,

he valve stems will be kept at a minimum

celifeoftheenginewillbegenerally

ice life for the engine bearings, the piston

ry fuel consumption.

The Water Temperature Regulator and Insulated

The engine is equipped with a water temperature regulator correct operating temperature jacket water circulates through the engine cylinder block and into the engine cy cylinder block via an internal passage that bypasses the valve of the coolant temperature regulator. This ensures t cold operating conditions. The water temperature regulator begins to open when the engine jacket water ha temperature. As the jacket water coolant temperature rises above the minimum operating temperature the water te more coolant through the radiator to dissipate excess heat.

The progressive opening of the water temperature regulator operates the progressive closing of the bypass head. This ensures maximum coolant ﬂow to the radiator in order to achieve maximum heat

pation.

dissi

Note: Perkins discourages the use of all air ﬂow

iction devices such as radiator shutters.

restr Restriction of the air ﬂow can result in the following: high exhaust temperatures, power loss, excessive fan us

Heater Lines

. When the engine coolant is below the

linder head. The coolant then returns to the

hat coolant ﬂows around the engine under

s reached the correct minimum operating

mperature regulator opens further allowing

passage between the cylinder block and

age, and reduction in fuel economy.

Page 37

SEBU8311-01 37

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Operation Section

Cold Weather Operation

A cab heater is b feed from the engine and the return lines from the cab should be insulated in order to reduce heat loss to the outside

eneﬁcial in very cold weather. The

air.

Insulating the Air Inlet a nd Engine Compartment

When temperatures below −18 °C (−0°F)willbe frequently e is located in the engine compartment may be speciﬁed. An air cleaner that is located in the engine compartment into the air cleaner. Also, heat that is rejected by the engine helps to warm the intake air.

Additional heat can be retained around the engine by insulating the engine compartment.

ncountered, an air cleaner inlet that

may also minimize the entry of snow

i02322217

Fuel and the Effect from Cold Weather

Note: Only use grades of fuel that are recommended

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

The following fuels can be used in this series of engine.

Group 1

•

Group 2

•

Group 3

•

Special Fuels

•

Perkins prefer only Group 1 and Group 2 fuels for use in this series of engines.

Group 1 fuels are the preferred Group of Fuels for general use by Perkins. Group 1 fuels maximize engine life and engine performance. Group 1 fuels are usually less available than Group 2 fuels. Frequently, Group 1 fuels are not available in colder climates during the winter.

Note: Group 2 fuels must have a maximum wear scar of 650 micrometers (HFRR to ISO 12156-1).

Group 2 fuels are considered acceptable for issues of warranty. This group of fuels may reduce the life of the engine, the engine’s maximum power, and the engine’s fuel efﬁciency.

When Group 2 die components provide a means of minimizing problems in cold weather:

Glow plugs (if equipped)

•

Engine coolan

•

option

Fuel heaters,

•

Fuel line insulation, which may be an OEM option

•

There are three major differences between Group 1 fuels and Group 2 fuels. Group 1 fuels have the following di

A lower cloud point

•

A lower pour point

•

A higher ener

•

Note: Group 3 fuels reduce the life of the engine. The use of Group 3 warranty.

Group3fuels Aviation Kerosene Fuels.

Special fuel

The cloud point is a temperature that allows wax crystals to the fuel ﬁlters to plug.

The pour poi will thicken. The diesel fuel becomes more resistant to ﬂow through fuel lines, fuel ﬁlters,and fuel pumps.

Be aware of these facts when diesel fuel is purchased. Consider the average ambient air temperatu that are fueled in one climate may not operate well if the engines are moved to another climate. Problems can result

Before troubleshooting for low power or for poor performan

Low temperature fuels may be available for engine operatio fuels limit the formation of wax in the fuel at low temperatures.

For more information on cold weather operation, refer to the Operation and Maintenance Manual, “Cold Weather O Cold Weather”.

fferent characteristics to Group 2 fuels.

s include Biofuel.

form in the fuel. These crystals can cause

re for the engine’s application. Engines

due to changes in temperature.

ce in the winter, check the fuel for waxing.

n at temperatures below 0 °C (32 °F). These

peration and Fuel Related Components in

sel fuels are used the following

t heaters, which may be an OEM

which may be an OEM option

gy per unit volume of fuel

fuelsisnotcoveredbythePerkins

include Low Temperature Fuels and

nt is the temperature when diesel fuel

Page 38

38 SEBU8311-01

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Operation Section Cold Weather Operation

i01903588

Fuel Related Components in Cold Weather

Fuel Tanks

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

Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks. Some fuel tan and sediment to settle below the end of the fuel supply pipe.

Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped wi the fuel system ﬁlter is important.

ks use supply pipes that allow water

th this system, regular maintenance of

Drain the wa tank at the following intervals: weekly, oil changes, and refueling of the fuel tank. This will help prevent water and/o fuel storage tank and into the engine fuel tank.

ter and sediment from any fuel storage

r sediment from being pumped from the

Fuel Filters

It is possi between the fuel tank and the engine fuel inlet. After you change the fuel ﬁlter, always prime the fuel system in o system. Refer to the Operation and Maintenance Manual in the Maintenance Section for more informat

The micron rating and the location of a primary fuel ﬁlter is i primary fuel ﬁlter and the fuel supply line are the most common components that are affected by cold fuel.

ble that a primary fuel ﬁlter is installed

rder to remove air bubbles from the fuel

ion on priming the fuel system.

mportant in cold weather operation. The

Fuel Heaters

Note: The OEM may equip the application with fuel

heaters. If this is the case, disconnect an electric type of fuel h overheating of the fuel. If the type of fuel heater is a heat exchanger, the OEM should have included a bypass f operational during warm weather in order to prevent overheating of the fuel.

eater in warm weather in order to prevent

or warm weather. Ensure that the bypass is

For more information about fuel heaters (if equipped), refer to the OEM information.

Page 39

SEBU8311-01 39

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Maintenance Section

Reﬁll Capacities

Maintenance Section

Reﬁll Capacities

i02959059

Reﬁll Capaci ties

Lubrication System

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

402D-05 Engine

Table 11

402D-05 Engine

Reﬁll Capacities

Compartment or System Minimum Maximum

Crankcase Oil Sump

Total Lubrication System

(1)

These values are the approximate capacities for the crankcase oil sump wh ich includes the standard factory installed oil ﬁlt ers. Engines with auxiliary oil ﬁlters will require additional oil. Refer to the OEM speciﬁcations for the capacity of the auxiliary oil ﬁlter.

(2)

The Total Lubrication System includes the capacity for the Crankcase Oil Sump plus the capacity of factory installed oil ﬁlters and other ﬁlters added to the lubrication system. Enter the value for the capacity of the Total Lubrication System in this row.

(1)

(2)

1.61 L

(1.7 qt)

2.01 L

(2.1 qt)

403D-07 Engine

Table 12

403C-07 Engine

Reﬁll Capacities

Compartment or System Minimum Maximum

Crankcase Oil Sump

Total Lubrication System

(1)

These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil ﬁ lters. Engines with aux iliary oil ﬁlters will require additional oil. Refer to the OEM speciﬁcations for the c apacity of the auxiliary oil ﬁlter.

(2)

The Total Lubrication System includes the c apacity for the Crankcase Oil Sump plus the capacity of factory installed oil ﬁlters and other ﬁlters added to the lubrication system. Enter the value for t he capacity of the Total Lubrication System in this row.

(1)

(2)

2.35 L

(2.5 qt)

3.05 L

(3.2 qt)

403D-11 Engine

Table 13

403D-11 Engine

Reﬁll Capacities

Compartment or System

Crankcase Oil Sump

Total Lubrication System

(1)

These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil ﬁ lters. Engines with aux iliary oil ﬁlters will require additional oil. Refer to the OEM speciﬁcations for the c apacity of the auxiliary oil ﬁlter.

(2)

The Total Lubrication System includes the c apacity for the Crankcase Oil Sump plus the capacity of factory installed oil ﬁlters and other ﬁlters added to the lubrication system. Enter the value for t he capacity of the Total Lubrication System in this row.

(1)

(2)

Minimum Maximum

3.4 L

(3.6 qt)

4.4 L

(4.6494

403D-15 and 403D-15T Engines

Table 14

403D-15 and 403D-15T Engines

Reﬁll Capacities

Compartment or System

Crankcase Oil Sump

Total Lubrication System

(1)

These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil ﬁ lters. Engines with aux iliary oil ﬁlters will require additional oil. Refer to the OEM speciﬁcations for the c apacity of the auxiliary oil ﬁlter.

(2)

The Total Lubrication System includes the c apacity for the Crankcase Oil Sump plus the capacity of factory installed oil ﬁlters and other ﬁlters added to the lubrication system. Enter the value for t he capacity of the Total Lubrication System in this row.

(1)

(2)

Minimum Maximum

4.5 L

(4.8 qt)

(6.3 qt)

qt)

Page 40

40 SEBU8311-01

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Maintenance Section Reﬁll Capacities

403D-17 Engine

Table 15

403D-17 Engine

Reﬁll Capaciti

Compartment or System

Crankcase Oil Sump

Total Lubrication System

(1)

(2)

(1)

(2)

Minimum Maximum

4.5 L

(4.8 qt)

(6.3 qt)

404D-15 Engine

Table 16

404D-15 Engine

Reﬁll Capacities

Compartment or System Minimum Maximum

Crankcase Oil Sump

Total Lubrication System

(1)

(2)

The Total Lub Crankcase O ﬁlters and o the value fo this row.

ther ﬁlters added to the lubrication system. Enter r the capacity of the Total Lubrication System in

(1)

(2)

rication System includes the capacity for the

il Sump plus the capacity of factory installed oil

3.9 L

(4.1211 qt)

5.6 L

(5.9175

qt)

404D-22, 404D-

22T and 404D-22TA

Engines

Table 17

404D-22, 404D-22T and 404D-22TA Engines

Reﬁll Capacities

Compartment or System Minimum Maximum

Crankcase Oil Sump

Total Lubrication System

(1)

More than one style of sump may be used on these engines. Use these values to estimate the reﬁll capacity. Use the engine oil level gauge to ﬁll the engine to the correct oil level. Record the result in this table. T hese values are the approximate capacities for the Crankcase O il Sump which includes the standard factory installed oil ﬁlters. Engines with auxiliary oil ﬁlters will require additional o il. Refer to the OEM speciﬁcations for the capacity of the auxiliary oil ﬁlter.

(2)

The Total Lubrication System includes the c apacity for the Crankcase Oil Sump plus the capacity of factory installed oil ﬁlters and other ﬁlters added to the lubrication system. Enter the value for t he capacity of the Total Lubrication System in this row.

(1)

(2)

8.9 L

(9.4 qt)

10.6 L

(11.2 qt)

Cooling System

To maintain the cooling system, the Total Cooling System capacity must be known. The approximate capacity is for the engine cooling system. External System capacities will vary among applications. Refer to the OEM speciﬁcations for the External System capacity. This capacity information will be needed in order to determine the amount of coolant that is required for the Total Cooling System.

402D-05 Engine

Table 18

402D-05 Engine

Reﬁll Capacities

Compartment or System

Engine Only

External System Per OEM

Total Cooling System

(1)

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

(2)

The Total Cooling System capacity includes the capacity of the Engine plus the External Sys tem. Enter the value for the capacity of the Total Cooling System in this row.

(1)

(2)

Liters

1.1 1.2

Quarts

Page 41

SEBU8311-01 41

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Maintenance Section

Reﬁll Capacities

403D-07 Engine

Table 19

403D-07 Engine

Reﬁll Capaciti

Compartment or System

Engine Only

External System Per OEM

Total Cooling System

(1)

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

(2)

The Total Cooling System capacity includes the ca pacity of the Engine plus the External S ystem. Enter the value for the capacity of the Total Cooling System in this row.

403D-11 Engin

Table 20

(1)

(2)

403D-11 Engine

Reﬁll Capacit

Compartment or System

Engine Only

External System Per OEM

Total Cooling System

(1)

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

(2)

The Total Cooling System capacity includes the ca pacity of the Engine plus the External S ystem. Enter the value for the capacity of the Total Cooling System in this row.

403D-15 and 4

(1)

(2)

03D-15T Engines

Liters

1.2 1.3

ies

Liters

1.9 2.0

Quarts

404D-15 Engine

Table 22

404D-15 Engine

Reﬁll Capaciti

Compartment or System

Engine Only

External System Per OEM

Total Cooling System

(1)

(2)

The Total Cooling System capacity includes the capacity of the Engine plus the External Sys tem. Enter the value for the capacity of the Total Cooling System in this row.

404D-22, 404D

(1)

(2)

-22T and 404D-22TA

Liters

2.4 2.5

Quarts

Engines

Table 23

404D-22,404D-22T and 404D-22TA Engines

Compartment or System Liters Quarts

Engine Only 3.6 3.8

External System Per OEM

Total Coolin

(1)

The External S tank with the piping. Refe capacity of t

(2)

The Total Cooling System capacity includes the capacity for the Engine plus the External Sys tem. Enter the value for the capacity of the Total Cooling System in this row.

Reﬁll Capacities

(1)

gSystem

r to the O E M speciﬁcations. Enter the value for the he External System in this row.

(2)

ystem includes a radiator or an expansion

following components: heat exchanger and

Table 21

403D-15 and 403D-15TEngines

Reﬁll Capaci

Compartment or System

Engine Only

External System Per OEM

Total Cooling System

(1)

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

(2)

The Total Cooling System capacity includes the ca pacity of the Engine plus the External S ystem. Enter the value for the capacity of the Total Cooling System in this row.

(2)

ties

Liters

Quarts

2.6 2.7

(1)

Fluid Recommendations

General Lubricant Inform a tion

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

Engine Manufacturers Association (EMA) Oils

vernment regulations regarding the

The “Engine Manufacturers Association Recommended Guideline on Diesel Engine Oil” is recognize

d by Perkins. For detailed information about this guideline, see the latest edition of EMA publication, “EMA DHD -1”.

i02959104

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42 SEBU8311-01

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Maintenance Section Reﬁll Capacities

API Oils

The Engine Oil Licensing and Certiﬁcation System by theAmericanP

etroleum Institute (API) is recognized by Perkins. For detailed information about this system, see the latest edition of the “API publication No. 1509”. En

gine oils that bear the API symbol are

authorized by API.

Illustration 29

Typical API symbol

g00546535

Diesel engine oils CC, CD, CD-2, and CE have not been API authorized classiﬁcations since 1 January 1996. Table 24 summarizes the status of the classiﬁcations.

Table 24

API Classiﬁcations

Current Obsolete

CF-4, CG-4, CH-4 CE

CF CC, CD

(1)

CF-2

(1)

The classiﬁcations CD-2 and American Petroleum Institute CF-2 are for two-cycle diesel engines. Perkins does not sell engines that utilize CD-2 and API CF-2 oils.

CD-2

(1)

Termin olo gy

Certain abbreviations follow the nomenclature of “SAE J754”. Some classiﬁcations follow “SAE J183” abbreviations, and some classiﬁcations follow the “EMA Recommended Guideline on Diesel Engine Oil”. In addition to Perkins deﬁnitions, there are other deﬁnitions that will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in this publication, “Fluid Recommendations/Engine Oil” topic (Maintenance Section).

Engine Oil

Commercial Oils

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

Only use commercial oils that meet the following classiﬁcations:

EMA DHD-1 multigrade oil (pre ferred oil)

•

API CH-4 multigrade oil (preferred oil)

•

ACEAE5

•

In order to make the correct choice of a commercial oil, refer to the following explanations:

EMA DHD-1 – The Engine Manufacturers Association (EMA) has developed lubricant recommendations as an alternative to the API oil classiﬁcation system. DHD-1 is a Recommended Guideline that deﬁnes a level of oil performance for these types of diesel engines: high speed, four stroke cycle, heavy-duty, and light duty. DHD-1 oils may be used in Perkins engines when the following oils are recommended: API CH-4, API CG-4, and API CF-4. DHD-1 oils are intended to provide superior 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 applications. The tests and the test limits that are used to deﬁne DHD-1 are similar to the new API CH-4 classiﬁcation. Therefore, these oils will also meet the requirements for diesel engines that require low emissions. DHD-1 oils are designed to control the harmful effects of soot with improved wear resistance and improved resistance to plugging of the oil ﬁlter. These oils will also provide superior control of piston deposits for engines with either two-piece steel pistons or aluminum pistons.

All DHD-1 oils must complete a full test program with the base stock and with the viscosity grade of the ﬁnishedcommercialoil.Theuseof“APIBase Oil Interchange Guidelines” are not appropriate for DHD-1 oils. This feature reduces the variation in performance that can occur when base stocks are changed in commercial oil formulations.

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Maintenance Section

Reﬁll Capacities

DHD-1 oils are r change interval programs that optimize the life of the oil. These oil change interval programs are based on oil analysi conditions that demand a premium oil. Your Perkins dealer or your Perkins distributor has the speciﬁc guidelines f

API CH-4 – API CH-4 oils were developed in order to meet the requ diesel engines. Also, the oil was designed to meet the requirements of the low emissions diesel engines. AP in older diesel engines and in diesel engines that usehighsulfurdieselfuel.APICH-4oilsmaybe used in Perk CF-4 oils. API CH-4 oils will generally exceed the performance of API CG-4 oils in the following criteria: deposits o of piston rings, valve train wear, viscosity control, and corrosion.

Three new engine tests were developed for the API CH-4 oil. The ﬁrsttestspeciﬁcally evaluates deposits on piston This test (piston deposit) also measures the control of oil consumption. A second test is conducted with mode the following criteria: wear of piston rings, wear of cylinder liners, and resistance to corrosion. A third new test high levels of soot in the oil: wear of the valve train, resistance of the oil in plugging the oil ﬁlter, and control

In addition to the new tests, API CH-4 oils have toughe generate high soot. The oils also have improved oxidation resistance. API CH-4 oils must pass an additi aluminum pistons (single piece). Oil performance is also established for engines that operate in areas with h

s for engines with the two-piece steel piston.

measures the following characteristics with

of sludge.

r limits for viscosity control in applications that

onal test (piston deposit) for engines that use

igh sulfur diesel fuel.

ecommended for use in extended oil

s. DHD-1 oils are recommended for

or optimizing oil change intervals.

irements of the new high performance

I CH-4 oils are also acceptable for use

ins engines that use API CG-4 and API

n pistons, control of oil consumption, wear

rate oil soot. The second test measures

NOTICE Failuretofoll shortened engine service life due to deposits and/or excessive wear.

Total Base Nu m

ow these oil recommendations can cause

ber (TBN) and Fuel Sulfur

Levels for Diesel Engines

The Total Base the fuel sulfur level. For engines that use distillate fuel, the minimum TBN of the new oil must be 10 times the f by “ASTM D2896”. The minimum TBN of the oil is 5 regardless of fuel sulfur level. Illustration 30 demonstrate

Illustration 30

(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.

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.

Number (TBN) for an oil depends on

uel sulfur level. The TBN is deﬁned

stheTBN.

g00799818

All of these improvements allow the API CH-4

achieve optimum oil change intervals. API

oil to CH-4 oils are recommended for use in extended oil change intervals. API CH-4 oils are recommended

nditions that demand a premium oil. Your

for co Perkins dealer or your Perkins distributor has speciﬁc guidelines for optimizing oil change intervals.

Some commercial oils that meet the API classiﬁcations may require reduced oil change

rvals. To determine the oil change interval, closely

inte monitor the condition of the oil and perform a wear metal analysis.

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.

Excessive piston deposits can be produced by an oil withahighTBN.Thesedepositscanleadtoaloss of control of the oil consumption and to the polishing of the cylinder bore.

NOTICE Operating diesel engines with fuel sulphur levels over

0.5 percent will require shortened oil change intervals in order to help maintain adequate wear protection.

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Maintenance Section Reﬁll Capacities

Table 25

Percentage of Sulfur in the fuel

Lower than 0.5 Normal

0.5 to 1.0

Greater than 1.0 0.50 of normal

Oil change interval

0.75 of normal

Lubricant Viscosity Recommendations

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

Refer to Table 26 (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 26

Engine Oil Viscosity

EMA LRG-1

API CH-4

Viscosity Grade

SAE 0W20 −40 °C (−40 °F) 10 °C (50 °F)

SAE 0W30 −40 °C (−40 °F) 30 °C (86 °F)

SAE 0W40 −40 °C (−40 °F) 40 °C (104 °F)

SAE 5W30 −30 °C (−22 °F) 30 °C (86 °F)

SAE 5W40 −30 °C (−22 °F) 40 °C (104 °F)

SAE 10W30 −20 °C (−4 °F) 40 °C (104 °F)

SAE 15W40 −10 °C (14 °F) 50 °C (122 °F)

Ambient Temperature

Minimum Maximum

Synthetic Base Stock Oils

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

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

Synthetic base oils have improved ﬂow at low

•

temperatures especially in arctic conditions.

Synthetic base oils have improved oxidation

•

stability especially at high operating temperatures.

base oils are acceptable for use in

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

Re-reﬁned Ba

Re-reﬁned base stock oils are acceptable for use in Perkin performance requirements that are speciﬁed by Perkins. Re-reﬁnedbasestockoilscanbeused exclusively new base stock oils. The US military speciﬁcations and the speciﬁcations of other heavy equipment manufactur stock oils that meet the same criteria.

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

Lubrican

When an engine is started and an engine is operated in ambien multigrade oils that are capable of ﬂowinginlow temperatures.

These oils have lubricant viscosity grades of SAE 0W or SAE 5W.

When an engine is started and operated in ambient temperatures below −30 °C (−22 °F), use a synthetic base sto orwitha5Wviscositygrade.Useanoilwithapour point that is lower than −50 °C (−58 °F).

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

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

Second Choic e – Use an oil that has a CH-4 additi tested for the requirements of the API license, the oil must be either SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W

ck multigrade oil with an 0W viscosity grade

ng lubricants for use in cold weather conditions:

ended Guideline. Use a CH-4 oil that has

ant viscosity grade.

ve package. Although the oil has not been

30, or SAE 5W40.

base oils have performance

he oil change intervals for any type of

se Stock Oils

s engines if these oils meet the

in ﬁnished oil or in a combination with

ers also allow the use of re-reﬁned base

that is used to make re-reﬁned base

sed oil. The process that is used to

iltering is adequate for the production of

ts for Cold Weather

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

Page 45

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Maintenance Section

Reﬁll Capacities

NOTICE Shortened engi choice oils are used.

ne service life could result if second

Aftermarket O il Additives

Perkins does not recommend the use of aftermarket additives in oil. It is not necessary to use aftermarket additives in o service life or rated performance. Fully formulated, ﬁnished oils consist of base oils and of commercial additive pac blended into the base oils at precise percentages in order to help provide ﬁnished oils with performance characteris

There are no industry standard tests that evaluate the performa additives in ﬁnished oil. Aftermarket additives may not be compatible with the ﬁnished oil’s additive package, wh ﬁnished oil. The aftermarket additive could fail to mix with the ﬁnished oil. This could produce sludge in the cran aftermarket additives in ﬁnished oils.

rder to achieve the engine’s maximum

kages. These additive packages are

tics that meet industry standards.

nce or the compatibility of aftermarket

ich could lower the performance of the

kcase. Perkins discourages the use of

The Wear Rate An

•

engine’s metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increase in th 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 com properties of the used oil sample. This analysis allows technicians to determine the amount of deteriorat also allows technicians to verify the performance of the oil according to the speciﬁcation during the entire oil c

ion of the oil during use. This analysis

hange interval.

alysis monitors the wear of the

e rate of engine wear metal in the

pare the properties of new oil to the

i02959102

Fluid Recommendations (Coolant Speciﬁcations)

To achieve engine, conform to the following guidelines:

Select the

•

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 an

Perform maintenance at the intervals that are

•

speciﬁed Manual, “Maintenance Interval Schedule”.

Oil analy

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

The oil analysis is a diagnostic tool that is used to determi rates. Contamination can be identiﬁed and measured through the use of the oil analysis. The oil analysis includ

the best performance from a Perkins

correct oil, or a commercial oil that meets

dinstallanewoilﬁlter.

in the Operation and Maintenance

sis

f oil analysis is required the oil sampling valve

ne oil performance and component wear

es the following tests:

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 eit ature or drained completely to prevent damage.

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

Clean the cooling system for the following reasons:

Contamina

•

Overheating of the engine

•

Foaming of the coolant

•

her protected to the lowest outside temper-

NOTICE

tion of the cooling system

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Maintenance Section Reﬁll Capacities

Additives

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

n engine without water temperature

ing temperature. Cooling system prob-

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

Corrosion

•

stem. A lack of coolant additives or

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

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.

ilures are related to the cooling

gged 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 he

Distilled water or deionized water is recommend

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

If distill use water with the properties that are listed in T able

27.

Table 27

at.

ed for use in engine cooling systems.

ard water, softened water that has been

ed water or deionized water is not available,

Acceptabl

Property Maximum Limit

Chloride (Cl) 40 mg/L

Sulfate (SO4) 100 mg/L

Total Hardness 170 mg/L

Total Solids 340 mg/L

Acidity pH of 5.5 to 9.0

e Water

Formation of m

•

Rust

•

Scale

•

Foaming of the

•

Many additives are depleted during engine operation. These additiv

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

Formation of gel compounds

•

Reduction of

•

Leakage of the water pump seal

•

Plugging of radiators, coolers, and small passages

•

ineral deposits

coolant

es must be replaced periodically.

ration of additives can cause the

heat transfer

Glycol

Glycol in the coolant helps to provide protection against the

Boiling

•

Freezing

•

Cavitation

•

For optimum performance, Perkins recommends a 1:1 mixture

Note: Use a mixture that will provide protection against the

Note: 100 percent pure glycol will freeze at a temperatu

following conditions:

of the water pump

of a water/glycol solution.

lowest ambient temperature.

re of −23 °C (−9°F).

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

Local water utility company

•

Agricultural agent

•

Independent laboratory

•

Most conventional antifreezes use ethylene glycol. Propylene with water, ethylene and propylene glycol provide similar protection against freezing and boiling. See Tables 28 a

glycolmayalsobeused.Ina1:1mixture

nd 29.

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Maintenance Section

Reﬁll Capacities

Table 28

Ethylene Glycol

Concentration Freeze Protection

50 Percent −36 °C (−33 °F)

60 Percent

−51 °C (−60 °F)

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

Table 29

Propylene Glycol

Concentration Freeze Protection

50 Percent −29 °C (−20 °F)

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

Coolant Recommendations

ELC____________________________ Extended Life Coolant

•

In stationary e

ngine applications and marine engine applications that do not require anti-boil protection or freeze protection, a mixture of SCA and water is acceptable

. Perkins recommends a six percent to eight percent concentration of SCA in those cooling systems. Distilled water or deionized water is preferred

. Water which has the recommended

properties may be used.

Table 30

Coolant Service Life

Coolant Type Service Life

Perkins ELC

Commercial Heavy-Duty

Antifreeze t

“ASTM D4985”

Perkins POWERPART

Commercial SCA and

hat meets

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

Perkins provides ELC for use in the following applications:

SCA___________________Supplement Coolant Additive

•

ASTM__________________________________________ American

•

Society for Testing and Materials

The following two coolants are used in Perkins diesel engines:

Preferred – Perkins ELC

Acceptable – A commercial heavy-duty antifreeze

that meets “ASTM D4985” speciﬁcations

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

Perkins recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide optimum heavy-duty performance as a antifreeze. Thisratiomaybeincreasedto1:2watertoglycolif extra freezing protection is required.

Note: A commercial heavy-duty antifreeze that meets “ASTM D4985” speciﬁcations MAY require a treatment with an SCA at the initial ﬁll. Read the label or the instructions that are provided by the OEM of the product.

Heavy-duty spark ignited gas engines

•

Heavy-duty diesel engines

•

Automotive applications

•

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

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

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

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Maintenance Section Reﬁll Capacities

ELC Cooling System Maintenance

NOTICE

Correct additions to the Extended Life Coolant

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

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

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

Do not use a conventional coolant to top-off a cooling system tha

Do not use standard supplemental coolant additive (SCA).

When using Perkins ELC, do not use standard SCA’s or SCA ﬁlte

commendations can reduce cooling sys-

NOTICE

tisﬁlled with Extended Life Coolant (ELC).

rs.

ELC Cooling System Cleaning

Note: If th

cleaning agents are not required to be used at the speciﬁed coolant change interval. Cleaning agents ar contaminated by the addition of some other type of coolant or by cooling system damage.

e cooling system is already using ELC,

e only required if the system has been

Care must b e tak contained during performance of inspection, maintenance, testing, adjusting and the repair of the product. Be pr containers before opening any compartment or disassembling any component containing ﬂuids.

Dispose of all ﬂuids according to local regulations and mandates.

1. Drain the cool

2. Dispose of the coolant according to local

regulations

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

4. Use Perkins cleaner to clean the system. Follow the instruct

5. Drain the cleaner into a suitable container. Flush the cooling

6. Fill the cooling system with clean water and operate the 49° to 66°C (120° to 150°F).

Incorrect o can result in damage to copper and other metal components.

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

7. Drain the c and ﬂushthecoolingsystemwithcleanwater.

r incomplete ﬂushing of the cooling system

o ﬂush the system until all the signs of the

en to ensure that all ﬂuids are

epared to collect the ﬂuid with suitable

ant into a suitable container.

bris.

ion on the label.

system with clean water.

engine until the engine is warmed to

NOTICE

ooling system into a suitable container

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

Before the cooling system is ﬁlled, the heater control (if equipped) must be set to the hot position. Refer to the OE the cooling system is drained and the cooling system is reﬁlled, operate the engine until the coolant level reaches until the coolant level stabilizes. As needed, add thecoolantmixtureinordertoﬁll the system to the speciﬁ

M in order to set the heater control. After

the normal operating temperature and

ed level.

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

8. Repeat St completely clean.

9. Fill the c ELC.

ooling system cleaner must be thoroughly

he cleaner may also corrode the cooling

eps6and7untilthesystemis

oolingsystemwiththePerkinsPremixed

Changing to Perkins ELC

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

Page 49

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Maintenance Section

Reﬁll Capacities

ELC Cooling Sys

Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life. Use only Perkins Products for premixed or concentrate coolants. 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 antifreeze or SCA. If the contamination exceeds ten percent of the total system capacity, perform ONE of the following procedures:

Drain the cooling system into a suitable container.

•

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

Drain a portion of the cooling system into a suitable

•

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

Maintain the system as a conventional Heavy-Duty

•

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

tem Contamination

NOTICE

Commercial Heavy -Duty Antifreeze and SCA

NOTICE Commercial Heavy-Duty Coolant which contains Amine as pa not be used.

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

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

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

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

rt of the corrision protection system must

NOTICE

Refer to Table 3 of SCA.

Table 31

Part Number

21825735 10

1 for part numbers and for quantities

Perkins Liquid SCA

Quantity

Adding the SCA to Heavy-Duty Coolant at the Initial Fill

Commercial heavy-duty antifreeze 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.

Use the equation that is in Table 32 to determine the amount of Perkins SCA that is required when the cooling system is initially ﬁlled.

Table 32

Equation For Adding The SCA To The Heavy-Duty

V is the total volume of the cooling s ystem.

X is the amount of SCA that is required.

Table 33 is an example for using the equation that is in Table 32.

Table 33

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant At The Initial Fill

Total Vol u m e

of the Cooling

System (V)

15 L (4 US gal)

Coolant At The Initial Fill

V×0.045=X

Multiplication

Factor

×0.045

Amount of

SCA that is

Required (X)

0.7 L (24 oz)

Adding The SCA to The Heavy-Duty Coolant For Maintenance

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

Test the antifreeze periodically for the concentration of SCA. For the interval, refer to the Operation and Maint 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

enance Manual, “Maintenance Interval

SCA that is needed.

Page 50

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Maintenance Section Reﬁll Capacities

Use the equatio amount of Perkins SCA that is required, if necessary:

Table 34

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.

Table35isanexampleforusingtheequationthat is in Table 34.

Table 35

Example Of The

The Heavy-Duty Coolant For Maintenance

Total Vol u m e

of the Cooling

System (V)

15 L (4 US gal)

n that is in Table 34 to determine the

Coolant For Maintenance

V × 0.014 = X

Equation For Adding The SCA To

Multiplication

Factor

× 0.014

Amount of

SCA that is

Required (X)

0.2 L (7 oz)

Cleaning the System of Heavy-Duty Antifreeze

LSD Low Sulfur D

•

ULSD Ultra Low Sulfur Diesel

•

RME Rape Methyl Ester

•

SME Soy Methyl

•

EPA Environmental Protection Agency of the

•

United States

General Infor

Every attempt i information. By use of this document you agree that Perkins Engines Company Limited is not responsible forerrorsoro

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

iesel

Ester

mation

NOTICE

smadetoprovideaccurate,uptodate

missions.

NOTICE

Diesel Fuel Requirements

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.

i02959101

Fluid Recommendations (Fuel Speciﬁcation)

Glossary

•

ISO International Standards Organization

•

ASTM American Society for Testing and Materials

•

Satisfactory use of a good quality fuel. The use of a good quality fuel will give the following results: long engine life and acceptable e meet the minimum requirements that are stated in tables 36, 37 and 38.

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

engine performance is dependent on the

xhaust emissions levels. The fuel must

NOTICE

HFRR High F

•

Lubricity testing of diesel fuels

FAM E Fatt

•

CFR Co-ordinating Fuel Research

•

requency Reciprocating Rig for

y Acid Methyl Esters

Page 51

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Maintenance Section

Reﬁll Capacities

Table 36

Perkins Speciﬁcation for Distillate Diesel Fuel

Property UNITS Requirements “ASTM”Test “ISO”Test

Aromatics %Volume 35% maximum D1319 “ISO”3837

Ash

Carbon Residue on

%Weight 0.02% maximum

%Weight 0.35% maximum

D482

D524

10% Bottoms

Cetane Number

(2)

Cloud Point °C

40 minimum

The cloud point must

D613/D6890 “ISO”5165

D2500 not exceed the lowest expected ambient temperature.

Copper Strip

No. 3 maximum D130 “ISO”2160

Corrosion

Density at 15 °C (59 °F)

Distillati

(3)

Kg / M

°C 10% at 282 °C

801 minimum and 876 maximum

No equivalent test

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

Flash Point °C legal limit D93 “ISO”2719

Thermal Stability

Minimum of 80%

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

Pour Point

°C 6°C(42.8°

F) minimum

D97 below ambient temperature

(1)(4)

Sulfur

%mass The level of sulfur

D5453/D26222 “ISO 20846 ”“ISO 20884” that is in the fuel is controlled by emissions regulations. Refer to Tables 37 and 38 for more information.

Kinematic Viscosity

(5)

“MM”2“/S (cSt)” The viscosity of the

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

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

Water

% weight 0.1% max

Sediment % weight 0.05% maximum

imum D1744 No equivalent test

D473

(1)

“ISO”6245

“ISO”4262

“ISO”3015

“ISO 3675 ”“ISO 12185”

“ISO”3016

“ISO”3405

“ISO”3735

(continued)

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Maintenance Section Reﬁll Capacities

(Table 36, contd)

Gums and Resins

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

(1)

This speciﬁca “ASTM D5453”, (LSD). LSD fue methods”. Ref

(2)

A fuel with a h igher cetane number is recommended in order to operate at a higher altitude or in cold weather.

(3)

“Via standards tables, the equivalent API gravity for the minimum density of 801 kg / m3(kilograms per cubic meter) is 45 and for the maximum density o f 876 kg / m

(4)

Regional regu regulations b fuels in terri for corrosion information,

(5)

The values of the fuel v iscosity are the values as the f uel is delivered to the fuel injection pumps. Fuel should also m eet the minimum viscosity requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the “ASTM D445” test method or the “ISO 3104” test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain 1.4 cSt or greater viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to 4.5 cSt at the fuel injection pump.

(6)

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

(7)

The lubricit or ASTM D6079 consult your can c ause pro

(6)

mg/100mL

(7)

tion includes the requirements for Ultra Low Sulfur Diesel (ULSD). U LS D fuel will hav e ≤ 15 ppm (0.0015%) sulfur. Refer to

“ASTM D2622”, or “ISO 20846, ISO 20 884” test methods. This speciﬁcation includes the requirements for Low Sulfur Diesel

l will have ≤ 500 ppm (0.05%) sulfur. Refer to following:“ASTM 5453, ASTM D2622”, “ISO 20846”, and “ISO 20884 test

er to Tables 37 and 38.

lations, national regulations or international regulations can require a fuel w ith a speciﬁc sulfur limit. Consult all applicable

efore selecting a fuel for a given engine application. Perkins fuel systems and engine components can operate on high sulfur

tories that are non-e missions regulated. Fuel sulfur levels affect exhaust em issions. High sulfur fuels also increase the potential

of internal components. F uel sulfur levels above 0.5% may signiﬁcantly shorten the oil change interval. For additional

refer to this manual, “Fluid recommendations (General lubricant Information)”.

y of a fuel is a concern with low sulfur and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1

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

fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. T hese additives

blems in the fuel system.

is 30”.

10 mg per 100 mL maximum

0.46 maximum D6079

D381

“ISO”6246

“ISO”12156-1

NOTICE

Operating wi

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

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

Diesel Fuel Characteristics

Perkins Recommendation

Cetane Numb

Fuel that has a high cetane number will give a shorter ignition de quality. Cetane numbers are derived for fuels against proportions of cetane and heptamethylnonane in the standard C test method.

Cetane num expected from current diesel fuel. However, a cetane number of 40 may be experienced in some territories. The Unite that can have a low cetane value. A minimum cetane value of 40 is required during average starting conditio for operations at high altitudes or in cold weather operations.

lay. This will produce a better ignition

d States of America is one of t he territories

ns. A higher cetane value may be required

FR engine. Refer to “ISO 5165” for the

bers in excess of 45 are normally

Fuel with a lo

w cetane number can be the root cause

of problems during cold start.

Viscosity

Viscosity is the property of a liquid of offering resistance increasing temperature. This decrease in viscosity follows a logarithmic relationship for normal fossil fuel. The c This is the quotient of the dynamic viscosity that is divided by the density. The determination of kinematic viscosity viscometers at standard temperatures. Refer to “ISO 3104” for the test method.

The viscosity of the fuel is signiﬁcant because fuel serves as a lubricant for the fuel system components. Fuel must the fuel system in both extremely cold temperatures and extremely hot temperatures. If the kinematic viscosit injection pump damage to the fuel injection pump can occur. This damage can be excessive scufﬁng and seiz restarting, stalling and loss of performance. High viscosity may result in seizure of the pump.

Perkins recommends kinematic viscosities of 1.4 and

4.5 mm2/sec that is delivered to the fuel injection pump.

to shear or ﬂow. Viscosity decreases with

ommon reference is to kinematic viscosity.

is normally by readings from gravity ﬂow

have sufﬁcient viscosity in order to lubricate

y of the fuel is lower than 1.4 cSt at the fuel

ure. Low viscosity may lead to difﬁcult hot

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Maintenance Section

Reﬁll Capacities

Density

Density is the mass of the fuel per unit volume at a speciﬁcte

mperature. This parameter has a direct inﬂuence on engine performance and a direct inﬂuence on emissions. This determines the heat output from a

given injected volume of fuel. This is generally quoted in the following kg/m at 15 °C (59 °F).

Perkins recommends a value of density of 841 kg/m in order to obtain the correct power output. Lighter fuels are acc

eptable but these fuels will not produce

the rated power.

Sulfur

The level of sulfur is governed by emissions legislatio or international regulations can require a fuel with a speciﬁc sulfur limit. The sulfur content of the fuel and the fue regulations for emissions.

Tables 37 a sulfur level for speciﬁc territories. Consult all applicable regulations before selecting the fuel for a given engi

Table 37

ns. Regional regulation, national regulations

l quality must comply with all existing local

nd 38 list the guidelines for the correct

ne application.

Territory

EPA Low Sulfur (500 ppm) maximum

Non-

Regulated

Territories

Fuel Requirements from 2007

Sulfur/ Power

Models 402D-

Sulfur limit of less than 4000 ppm

Low sulfur (300 ppm)

maximum

for less than

or equal to

19 kW

05 and 403D-07

Sulphur

(1000 ppm)

maximum

for greater

than 19 kW

403D-11, 403D-15, 403D-15T, 403D-17, 404D-15. 404D-22, 404D22T and 404D-22TA

Table 38

Territory Fuel Requirements from 2010

EPA Ultra Low Sulfur (15 ppm) maximum

Non

Regulated

Territories

Sulfur/ Power

Models 402D-05,

Sulfur limit of less than 4000 ppm

Ultra Low

sulphur

(10 ppm)

maximum

for less than

or equal to

37 kW

403D-07, 403D-11, 403D-15, 403D-15T, 403D-17, 404D-15

Low sulphur

(300 ppm)

maximum

for greater

than 37 kW

404D-22, 404D22T and 404D-22TA

By using the test methods “ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884”, the content of sulfur in low sulfur diesel (LSD) fuel must be below 500 PPM 0.05%. By using the test methods “ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884”, the content of sulfur in ultra low sulfur (ULSD) fuel must be below 15 PPM 0.0015%. The lubricity of these fuels must not exceed wear scar diameter of

0.46 mm (0.0181 inch). The fuel lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to “ISO 12156-1 ”.

In some parts of the world and for some applications, high sulfur fuels above 0.5% by mass might only be available. Fuel with very high sulfur content can cause engine wear. High sulfur fuel will have a negative impact on emissions of particulates. High sulfur fuel can be used provided that the local emissions legislation will allow the use. High sulfur fuel can be used in countries that do not regulate emissions.

When only high sulfur fuels are available, it will be necessary that high alkaline lubricating oil is used in the engine or that the lubricating oil change interval is reduced. Refer to this Operation and Maintenance Manual, “Fliud Recommendations (Genernal Lubrication Information)” for information on sulfur in fuel.

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Maintenance Section Reﬁll Capacities

Lubricity

This is the capability of the fuel to prevent pump wear. The ﬂuid ﬂuid to reduce the friction between surfaces that are under load. This ability reduces the damage that is caused by fri lubricating properties of the fuel. Until fuel sulfur limits were mandated, the fuel’s lubricity was generally believed to b

The lubricity has particular signiﬁcance to the current low viscosit fossil fuel. These fuels are made in order to meet stringent exhaust emissions. A test method for measuring t developed and the test is based on the HFRR method that is operated at 60 °C (140 °F). Refer to “ISO 12156 p the test method.

Lubricity MUST NOT be exceeded. The fuel lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to “I

Fuel additives can enhance the lubricity of a fuel. Contact y when fuel additives are required. Your fuel supplier can make recommendations for additives to use and for th Additive” for more information.

Distilla

’s lubricity describes the ability of the

ction. Fuel injection systems rely on the

e a function of fuel viscosity.

y fuel, low sulfur fuel and low aromatic

he lubricity of diesel fuels has been

art 1 and CEC document F06-A-96” for

wear scar diameter of 0.46 mm (0.0181 inch)

SO 12156-1 ”.

our fuel supplier for those circumstances

e proper level of treatment. Refer to “Fuel

tion

Table 39

Fuel Groups Classiﬁcation

Group 1 Preferred fuels Full life of the

Product

Group 2 Permissible fuels These fuels

Group 3 Aviation fuels These fuels

Group 4

Biodiesel

MAY cause reduced engine l ife and performance

WILL cause reduced engine l ife and performance

Group 1 Speciﬁcations (Preferred Fuels)

This group of fuel speciﬁcations is considered acceptable:

EN590 DERV Grade A, B, C, E, F, Class, 0, 1, 2,

•

3, and 4

“ASTM D975”, Grade 2D S15, and Grade 2D S500

•

“JIS K2204 Grades 1,2,3 and Special Grade 3”

•

This grade of fuel must meet the minimum lubricity requirements that are stated in table 36.

“BS2869 Class A2” Off-Highway Gas Oil Red

•

Diesel

This is an indication of the mixture of different hydroca hydrocarbons can affect the characteristics of combustion.

rbons in the fuel. A high ratio of light weight

Classiﬁcation of the Fuels

Diesel e of fuels. These fuels are divided into four general groups: Ref to table 39

ngines have the ability to burn a wide variety

Note: BS2869 can only be used if the sulfur level meets the speciﬁcations that are listed in tables 37 and 38. An analysis of a sample of fuel must be conducted in order to check the sulfur level.

Note: The use of LSD fuel and the use of ULSD fuel is acceptable provided that the fuels meet the minimum requirements that are stated in tables 36, 37 and 38. The lubricity of these fuels must not exceed wear scar diameter of 0.46 mm (0.0181 inch). The lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to “ISO 12156-1 ”. By using the test methods “ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884”, the content of sulfur in LSD fuel must be below 500 PPM 0.05%. By using the test methods “ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884”, the content of sulfur in ULSD fuel must be below 15 PPM 0.0015%.

Group 2 Speciﬁcations (Permissible Fuels)

This group of fuel speciﬁcations is considered acceptable, but these fuels MA Y reduce the engine life and performance.

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Maintenance Section

Reﬁll Capacities

“ASTM D975”, Gr

•

“JP7 (MIL-T-38219)”

•

“NATO F63”

•

Note: JP7 and N sulfur level meets the speciﬁcations that are listed in tables 37 and 38. An analysis of a sample of fuel must be conduc

ade 1D S15, and Grade 1D S500

ATOF63canonlybeusedifthe

ted in order to check the sulfur level.

Group 3 Speciﬁcations (Aviation Fuels)

This group of fuel speciﬁcation must be used only with the appropriate fuel additive. This fuel WILL reduce engin

“NATO F34 (MIL-DTL-83133E)”

•

“NATO F35 (MIL-DTL-83133E)”

•

“NATO JP8 (MI

•

“NATO F-44 (MIL-DTL-5624U)”

•

“NATO JP5 (MIL-DTL-5624U)”

•

“Jet A (ASTM D

•

“Jet A1 (ASTM D1655)”

•

Note: All the above fuels can ONLY be used if the sulfur level meets the speciﬁcations that are listed in tables 37 a must be conducted in order to check the sulfur level.

Note: These thatthesefuelsareusedwithanappropriatefuel additive. These fuels must meet the requirements that are sta should be analyzed for the compliance. These fuels MUST NOT exceed lubricity wear scar diameter of

0.46 mm (0. performed on a HFRR, operated at 60 °C (140 °F). Refer to “ISO 12156-1 ”. Fuels must have minimum viscosity injection pump. Fuel cooling may be required in order to maintain minimum viscosity of 1.4 centistokes that is delive

e life and performance.

L-DTL-83133E)”

1655)”

nd 38. An analysis of a sample of fuel

fuels are only acceptable provided

ted in tables 36, 37 and 38. Fuel samples

0181 inch). The fuel lubricity test must be

of 1.4 centistokes that is delivered to the fuel

red to the fuel injection pump.

Group 4 Biodies

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

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

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

Recommendation for the use of biodiesel

The neat biodiesel must conform to “EN14214” or “ASTM D675” regulations. A maximum of 10% mixture The mineral diesel fuel must conform to “EN590”, “ASTM D975” or “BS2869 Grade A2” regulations.

In North America, biodiesel and mixtures of biodiesel must be purchased from the BQ9000 authorized manufa

In other areas of the world, the use of biodiesel that is author quality body is required.

y acids. Biodiesel is a fuel that can

(REM). This biodiesel is derived from

om soybean oil. Soybean oil or rapeseed

thout esteriﬁcation, these oils gel in the

hat are manufactured today. In original

may include animal tallow, waste cooking

teriﬁed.

ﬁed by use of the prescribed Environmental

user of the engine has the responsibility

iate regulatory agencies.

of biodiesel can be used in mineral diesel fuel.

cturers and BQ9000 certiﬁed distributors.

ized and certiﬁed by an appropriate biodiesel

When biodiesel, or any blend of biodiesel is

Note:

used, the user has the responsibility for obtaining the proper local exemptions, regional exemptions, and/or

nal exemptions that are required for the use

natio of biodiesel in any Perkins engine that is regulated by emissions standards. Biodiesel that meets

214” is acceptable. The biodiesel must be

“EN14 blended with an acceptable distillate diesel fuel at the maximum stated percentages. However, the following

ational recommendations must be followed:

oper

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Maintenance Section Reﬁll Capacities

The oil change i

•

nterval can be affected by the use of biodiesel. Use Services Oil Analysis in order to monitor the condition of the engine oil. Use Services Oil A

nalysis also in order to determine the

oil change interval that is optimum.

Conﬁrm that b

•

iodiesel is acceptable for use with

the manufacturer of the fuel ﬁlters.

In a comparis

•

on of distillate fuels to biodiesel, biodiesel provides less energy per gallon by 5% to 7%.DoNOTchangetheengineratinginorderto compensate f

or the power loss. This will help avoid engine problems when the engine is converted back to 100 percent distillate diesel fuel.

The compatibility of the elastomers with biodiesel

•

is being monitored. The condition of seals and hoses shoul

Biodiesel may pose low ambient temperature

•

problems f

d be monitored regularly.

or both storage and operation. At low ambient temperatures, fuel may need to be stored in a heated building or a heated storage tank. The fuel syste

m may require heated fuel lines, ﬁlters, and tanks. Filters may plug and fuel in the tank may solidify at low ambient temperatures if precautions are not ta

ken. Consult your biodiesel supplier for assistance in the blending and attainment of the proper cloud point for the fuel.

Biodiesel has poor oxidation stability, which

•

can result in long term problems in the storage of biodie

sel. The poor oxidation stability may accelerate fuel oxidation in the fuel system. This is especially true in engines with electronic fuel sys

tems because these engines operate at higher temperatures. Consult the fuel supplier for oxidation stability additives.

Biodiesel is a fuel that can be made from a variety

•

of feedstock. The feedstock that is used can

the performance of the product. Two of the

affect characteristics of the fuel that are affected are cold ﬂow and oxidation stability. Contact your fuel

er for guidance.

suppli

Biodiesel or biodiesel blends are not recommended

•

for eng

ines that will operate occasionally. This is due to poor oxidation stability. If the user is prepared to accept some risk, then limit biodiesel to a ma

ximum of B5. Examples of applications that should limit the use of biodiesel are the following: Standby Generator sets and certain emergency

les

vehic

Biodiesel is an

•

excellent medium for microbial contamination and growth. Microbial contamination and growth can cause corrosion in the fuel system and premature

plugging of the fuel ﬁlter. The use of conventionalanti-microbial additives and the effectiveness of conventional anti-microbial additives in

biodiesel is not known. Consult your

supplier of fuel and additive for assistance.

Care must be t

•

aken in order to remove water from fuel tanks. Water accelerates microbial contamination and growth. When biodiesel is compared to

distillate fuels, water is naturally more

likely to exist in the biodiesel.

Fuel for Col

d Weather Operation

The European standard “EN590” contains climate dependant r

equirements and a range of options. The options can be applied differently in each country. There are 5 classes that are given to arctic climates and severe

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

Fuel that complies with “EN590” CLASS 4 can be used at tem

peraturesaslowas−44 °C (−47.2 °F). Refer to “EN590” for a detailed discretion of the physical properties of the fuel.

The diesel fuel “ASTM D975 Grade 1-D S15 or S500” that is used in the united states of america may be used in ve

ry cold temperatures that are below −18 °C

(−0.4 °F).

In extrem

e cold ambient conditions, you may also use fuels that are listed in the table 40. These fuels are intended to be used in temperatures that can be as low as

Table 40

Speciﬁcation Grade

“MIL-DTL-5624U” JP-5

“MIL-DTL-83133E” JP-8

“ASTM D1

(1)

The use o additiv are stat analyze mm lubri The test Fuels m is deli be requ centis

−54 °C (−65.2 °F).

Light Distillate Fuels

655” Jet-A-1

f these fuels is ac ceptable with an appropriate fuel

e and the fuels must meet minimum requirements that

ed in Tables 36, 37 an d 38 . Fuel samples s hould be

d for the compliance. Fuels MUST NOT exceed 0.46

city wear scar diam ete r that is tested on a HFFR . must be performed at 60 °C. Refer to “ISO 12156 -1”.

ust have minimum viscosity of 1 .4 centistokes that

vered to the fuel injection pump. Fuel cooling may

ired in order to maintain minimum viscosity of 1.4

tokes that is delivered to the fuel injection pum p.

(1)

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Maintenance Section

Reﬁll Capacities

Mixing alcohol or gasoline with diesel fuel can produce an explosive mixture in the engine crankcase or the fuel tank. Alcohol or gasoline must not be used in order to dilute diesel fuel. Failure to follow this instruction may result in death or personal injury.

There are many other diesel fuel speciﬁcations that are published by governments and by technological societies. Usually, those speciﬁcations do not review all the requirements that are addressed in tables 36, 37 and 38. 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 stated in the tables 36, 37 and 38.

Fuel Additive

Supplemental diesel fuel additives are not generally recommended. This is due to potential damage to the fuel system or the engine. Your fuel supplier or the fuel manufacturer will add the appropriate supplemental diesel fuel additives.

Perkins recognizes the fact that additives may be required in some special circumstances. Fuel additives need to be used with caution. The additive may not be compatible with the fuel. Some additives may precipitate. This action causes deposits in the fuel system. The deposits may cause seizure. Some additives may be corrosive, and some additives may be harmful to the elastomers in the fuel system. Some additives may raise fuel sulfur levels above the maximum that is allowed by the EPA or the other regulatory agencies. Contact your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can recommend the appropriate fuel additive and the correct level of treatment.

Note: For the best results, your fuel supplier should treat the fuel when additives are required. The treated fuel must meet the requirements that are stated in tables 36, 37 and 38.

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Maintenance Section Maintenance Interval Schedule

i02965846

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 60

Battery or Battery Cable - Disconnect .................. 61

Engine - Clean ...................................................... 6

Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 68

Engine Air Clea

Inspect/Replace .................................................. 70

Fuel System - Prime ............................................. 76

Severe Service

Daily

Cooling System

Driven Equipment - Check .................................... 67

Engine Air Cleaner Service Indicator - Inspect ..... 70

Engine Air Prec

Engine Oil Level - Check ...................................... 72

Fuel System Primary Filter/Water Separator -

Drain ................................................................... 82

Walk-Around Inspection ........................................ 87

ner Element (Single Element) -

Application - Check ..................... 85

Coolant Level - Check ................ 65

leaner - Check/Clean ................... 71

Engine Crankca

Engine Mounts - Inspect ....................................... 72

Starting Motor - Inspect ........................................ 86

Every 3000 Serv

Fuel Injector - Test/Change ................................... 75

Water Pump - Ins

Every 6000 Service Hours or 3 Years

Cooling System

Change ............................................................... 62

Cooling System Coolant Extender (ELC) - Add .... 65

Every 12 000 Ser

Cooling System Coolant (ELC) - Change ............. 63

se Breather - Replace ................. 71

ice Hours

pect ........................................... 88

Coolant (Commercial Heavy-Duty) -

vice Hours or 6 Years

Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 83

Every 250 Service Hours or 6 Months

Alternator and Fan Belts - Inspect/Adjust ............. 59

Every 500 Service Hours

Fuel System Filter - Replace ................................ 80

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 61

Cooling System Supplemental Coolant Additive

(SCA) - Test/Ad Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 68

Engine Air Clean

Inspect/Replace .................................................. 70

Engine Oil and Filter - Change ............................. 73

Hoses and Clamp

Radiator - Clean .................................................... 84

d ................................................. 66

er Element (Single Element) -

s - Inspect/Replace .................. 83

Every 1000 Service Hours

Alternator and Fan Belts - Replace ....................... 60

Engine Valve Lash - Inspect/Adjust ...................... 74

Turbocharger - I

nspect .......................................... 86

Every 2000 Service Hours

Alternator - Ins

pect ............................................... 59

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Maintenance Section

Alternator - Inspect

i02322311

Alternator - Inspect

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

Check the alternator and the battery charger for correct oper charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries s affects the cranking power. If the battery is too cold, the battery will not crank the engine. When the engine is no engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easil

ends a scheduled inspection of

uipped) during engine operation in

equired.

ation. If the batteries are correctly

hould be kept warm because temperature

t run for long periods of time or if the

y than a battery with a full charge.

i02665597

Alternator and Fan Belts Inspect/Adjust

Illustration 31

Typical example

(1) Burroughs Gauge

Install the gauge (1) at the center of the belt between the alternator and the crankshaft pulley and check the belt tension. The correct tension for a new belt is 400 N (90 lb) to 489 N (110 lb). The correct tension for a used belt that has been in operation for 30 minutes or more at the rated speed is 267 N (60 lb) to356N(80lb).

If twin belts are installed, check and adjust the tensiononbothbelts.

g01003936

Adjustment

Inspection

To maximize the engine performance, inspect the belts for wear and for cracking. Replace belts that are worn or damaged.

For applications that require multiple drive belts, replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched. The additional load on the new belt could cause the new belt to break.

If the belts are too loose, vibration causes unnecessary wear on the belts and pulleys. Loose belts may slip enough to cause overheating.

To accurately check the belt tension, a suitable gauge should be used.

Illustration 32

Typical example

(1) Adjusting bolt (2) M ounting bolts

1. Loosen mounting bolts (2) and adjusting bolt (1).

g01091158

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60 SEBU8311-01

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Maintenance Section Alternator and Fan Belts - Replace

2. Move the altern

decrease the belt tension.

3. Tighten adjus

(2). Refer to the Speciﬁcations Manual for the correct torque settings.

ator in order to increase or

ting bolt (1). Tighten mounting bolts

Alternator and Fan Belts Replace

i02166560

i02322315

Battery - Replace

Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. T jury or death.

Ensure prope an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteri serviced.

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

his can result in severe personal in-

r ventilation for batteries that are in

es. Do not smoke when batteries are

Illustration 33

Typical exam p le

(1) Adjusting bolt (2) Mounting bolts

Note: When new belts are installed, check the belt tension again after 20 hours of engine operation.

Refer to the Disassembly and Assembly Manual for the installation procedure and the removal procedure for the belt.

g01091158

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

1. Switch the engine to the OFF position. Remove

all electrical loads.

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

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

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

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

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure that

theenginestartswitchisOFF.

7. Connect the cable from the starting motor to the POSITIVE “+” battery terminal.

Page 61

SEBU8311-01 61

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Maintenance Section

Battery Electrolyte Level - Check

8. Connect the NEG “-” battery terminal.

ATIVE“-”cabletotheNEGATIVE

i02747977

Battery Electrolyte Level Check

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

All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries.

1. Remove the ﬁller caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artiﬁcially softened water.

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

3. Install the caps.

4. Keep the batteries clean.

i02323088

Battery or Battery Cable Disconnect

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

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

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

ignition sw and remove the key and all electrical loads.

2. Disconnect that the cable cannot contact the terminal. When four 12 volt batteries are involved, two negative connection

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 s remove material excessively. Excessive removal ofmaterialcancausetheclampstonotﬁt correctly a suitable silicone lubricant or petroleum jelly.

the battery cover in place. The bat-

personal injury.

itch (if equipped) to the OFF position

the negative battery terminal. Ensure

must be disconnected.

urfaces are bright or shiny. DO NOT

. Coat the clamps and the terminals with

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

Use a solution of 0.1 kg (0.2 lb) baking soda

•

and 1 L (1 qt) of clean water.

Use a solution of ammonium hydroxide.

•

Thoroughly rinse the battery case with clean water.

6. Tap e th e c prevent accidental starting.

7. Proceed w

8. In order to connect the battery, connect the

positive

able connections in order to help

ith necessary system repairs.

connection before the negative connector.

Page 62

62 SEBU8311-01

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

i02595666

Cooling System Coo lant (Commercial H

eavy-Duty) -

Change

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

Dispose of all ﬂuids according to Local regulations and mandates.

NOTICE Keep all part

Contaminants may cause rapid wear and shortened component li

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

The engine overheats frequently.

•

Foaming is observed.

•

The oil has entered the cooling system and the

•

coolant is contaminated.

The fuel has entered the cooling system and the

•

coolant is contaminated.

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

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

Drain

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

s clean from contaminants.

fe.

1. Stop the engine Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller c

Illustration 34

Typical example

2. Open the drain cock or remove the drain p lug (1) on the engine. Open the drain cock or remove the drain plug on the radiator.

Allow the coolant to drain.

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

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

and allow the engine to cool.

ap.

g01301065

NOTICE

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

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

Cooling system air locks may result in engine damage.

Page 63

SEBU8311-01 63

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Maintenance Section

Cooling System Coolant (ELC) - Change

3. Fill the coolin cooling system ﬁller cap.

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

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

g system with clean water. Install the

he engine at low idle until the

e and allow the engine to cool.

cap. Open the drain cock or remove

rain. Flush the cooling system with

Fill

1. Close the dra

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

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

Cooling system air locks may result in engine damage.

in cock or install the drain plug on the

NOTICE

6. Start the engin leaks and for correct operating temperature.

e. Inspect the cooling system for

i02595733

Cooling System Co ola nt (ELC)

-Change

NOTICE Care must be taken to ensure that ﬂuids are contained during perfo ing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compa nent containing ﬂuids.

Dispose of al mandates.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

rmance of inspection, maintenance, test-

rtment or disassembling any compo-

l ﬂuids according to Local regulations and

NOTICE

2. Fill the coo Heavy-Duty Coolant. Add Supplemental Coolant Additive to the coolant. For the correct amount, refer to th “Fluid Recommendations” topic (Maintenance Section) for more information on cooling system speciﬁcat ﬁller cap.

3. Start and engine rpm to high idle. Run the engine at high idle for one minute in order to purge the air from the cavit

4. Check the coolant level. Maintain the coolant level within 13 pipe for ﬁlling. Maintain the coolant level in the expansion bottle (if equipped) at the correct level.

5. Clean the cooling system ﬁller cap. Inspect the gasket that is on the cooling system ﬁller cap. If the gask is damaged, discard the old cooling system ﬁller cap and install a new cooling system ﬁller cap. If the gask is not damaged, use a suitable pressurizing pump in order to pressure test the cooling system ﬁller cap. Th ﬁller cap is stamped on the face of the cooling system ﬁller cap. If the cooling system ﬁller cap does no cooling system ﬁller cap.

ling system with Commercial

e Operation and Maintenance Manual,

ions. Do not install the cooling system

run the engine at low idle. Increase the

ies of the engine block. Stop the engine.

mm (0.5 inch) below the bottom of the

et that is on the cooling system ﬁller cap

e correct pressure for the cooling system

t retain the correct pressure, install a new

Clean the cooling system and ﬂush the cooling system befo interval if the following conditions exist:

The engine o

•

Foaming is observed.

•

The oil has entered the cooling system and the

•

coolant is contaminated.

The fuel has entered the cooling system and the

•

coolant is contaminated.

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

Note: Inspect the water pump and the water temperatu been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hoses

re the recommended maintenance

verheats frequently.

re regulator after the cooling system has

,ifnecessary.

Page 64

64 SEBU8311-01

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Maintenance Section Cooling System Coolant (ELC) - Change

Drain

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

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

Loosen the cooling system ﬁller cap slowly in order to reli system ﬁller cap.

stem: Hot coolant can cause seri-

e cool. Loosen the cooling system

eve any pressure. Remove the cooling

Flush

1. Flush the cooli

to remove any debris.

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

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

Cooling system air locks may result in engine damage.

3. Fill the cooli cooling system ﬁller cap.

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

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

ng system with clean water in order

cock or install the drain plug in the

NOTICE

ng system with clean water. Install the

he engine at low idle until the

ne and allow the engine to cool.

cap. Open the drain cock or remove

drain. Flush the cooling system with

Illustration 35

Typical exam p le

2. Open the drain cock or remove the drain plug (1) on the engine. Open the drain cock or remove the drainplugontheradiator.

Allow the coolant to drain.

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

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

g01301065

Fill

1. Close the dr

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

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

Cooling system air locks may result in engine damage.

2. Fill the co Coolant (ELC). Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Mai on cooling system speciﬁcations. Do not install the cooling system ﬁller cap.

3. Start and run the engine at low idle. Increase the engine rpm to high idle. Run the engine at high idle for o the cavities of the engine block. Stop the engine.

4. Check the within 13 mm (0.5 inch) below the bottom of the pipe for ﬁlling. Maintain the coolant level in the expansi

ain cock or install the drain plug on the

NOTICE

oling system with Extended Life

ntenance Section) for more information

ne minute in order to purge the air from

coolant level. Maintain the coolant level

on bottle (if equipped) at the correct level.

Page 65

SEBU8311-01 65

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Maintenance Section

Cooling System Coolant Extender (ELC) - Add

5. Clean the cooli gasket that is on the cooling system ﬁller cap. If the gasket that is on the cooling system ﬁller cap is damaged, di cap and install a new cooling system ﬁller cap. If the gasket that is on the cooling system ﬁller cap is not damage in order to pressure test the cooling system ﬁller cap. The correct pressure for the cooling system ﬁller cap is system ﬁller cap. If the cooling system ﬁller cap does not retain the correct pressure, install a new cooling sys

6. Start the engine. Inspect the cooling system for leaks and fo

ng system ﬁller cap. Inspect the

scard the old cooling system ﬁller

d,useasuitablepressurizingpump

stamped on the face of the cooling

tem ﬁller cap.

r correct operating temperature.

i02335364

Cooling System Coo lant Extender (ELC) - Add

The Perkins Extended Life Coolant (ELC) does not need the frequent addition of Supplemental Coolant Additives (SCA) that are associated with conventional coolants. The Extender only needs to be added once.

Check the cooling system only when the engine is stopped and cool.

i02335378

Cooling System Coolant Leve l

- Check

Engines With a Coolant Recovery Tank

Note: The cool

provided by Perkins. The procedure that follows is for typical cooling systems. Refer to the OEM information

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

1. Observe the coolant level in the coolant recovery tank. Maint mark on the coolant recovery tank.

Pressurized System: Hot coolant can cause serious burns. T stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure c sure.

ing system may not have been

for the correct procedures.

ain the coolant level to “COLD FULL”

o open the cooling system ﬁller cap,

ap slowly in order to relieve the pres-

1. Loosen the cooling system ﬁller cap slowly in

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

2. It may be necessary to drain enough coolant from the cooling system in order to add the Extender.

3. Add Extender according to the requirements for your engine’s cooling system capacity. Refer to this Operation and Maintenance Manual, “Reﬁll Capacities” in the Maintenance Section for the capacity of the cooling system for your engine. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” information for the Perkins ELC Extender.

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

2. Loosen ﬁll pressure. Remove the ﬁller cap.

3. Pour the co Refer to the Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations” for informat coolant. Refer to the Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations” for the co coolant recovery tank above “COLD FULL” mark.

Illustration 36

er cap slowly in order to relieve any

rrect coolant mixture into the tank.

iononthecorrectmixtureandtypeof

oling system capacity. Do not ﬁll the

g00103639

Page 66

66 SEBU8311-01

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

4. Clean ﬁller cap ﬁller cap and inspect the cooling system for leaks.

Note: The cool up during normal engine operation. The additional volume will be forced into the coolant recovery tank during engin and cool, the coolant will return to the engine.

and the receptacle. Reinstall the

ant will expand as the coolant heats

e operation. When the engine is stopped

Engines Without a Coolant Recovery Tan

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

i02335389

Cooling System Supplemental Coolant Addit

ive (SCA) -

Test/Add

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

Test for SCA Concentration

Heavy-Duty Coolant/Antifreeze and SCA

NOTICE Do not exceed mental coolant additive concentration.

the recommended six percent supple-

Illustration 37

Cooling sys tem ﬁller cap

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

1. Remove th

order to relieve pressure.

2. Maintain of the bottom of the ﬁller pipe. If the engine is equipped with a sight glass, maintain the coolant level to

3. Clean the cooling system ﬁller cap and inspect the gasket. ﬁller cap and install a new ﬁller cap. If the gasket is not damaged, use a suitable pressurizing pump in order pressure is stamped on the face of the ﬁller cap. If the ﬁller cap does not retain the correct pressure, instal

To open the cooling system ﬁller cap,

cap slowly in order to relieve the pres-

e cooling system ﬁller cap slowly in

thecoolantlevelwithin13mm(0.5inch)

the correct level in the sight glass.

If the gasket is damaged, discard the old

to pressure test the ﬁller cap. The correct

l a new ﬁller cap.

g00285520

Use a Coolant Conditioner Test Kit in order to check the concentr

Add the SCA, I

Do not exceed the recommended amount of supplemental c supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling sys characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature comp additive concentration could also result in radiator tube blockage, overheating, and/or accelerated water pump seal w coolant additive and the spin-on element (if equipped) at the same time. The use of those additives together could res tration exceeding the recommended maximum.

ation of the SCA.

f Necessary

NOTICE

oolant additive concentration. Excessive

tem, reducing the engine’s heat transfer

onents. Excessive supplemental coolant

ear. Never use both liquid supplemental

ult in supplemental coolant additive concen-

4. Inspect the cooling system for leaks.

Page 67

SEBU8311-01 67

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Maintenance Section

Driven Equipment - Check

1. Slowly loosen t order to relieve the pressure. Remove the cooling system ﬁller cap.

Note: Always discard drained ﬂuids according to local regulations.

2. If necessary, drain some coolant from the cooling system into a suitable container in order to allow space for the

3. Add the correct amount of SCA. Refer to the Operation an Capacities and Recommendations” for more information on SCA requirements.

4. Clean the cooling system ﬁller cap and inspect the gasket. If the gasket is damaged, discard the old ﬁller cap an is not damaged, use a suitable pressurizing pump in order to pressure test the ﬁller cap. The correct pressure i the ﬁller cap does not retain the correct pressure, install a new ﬁller cap.

he cooling system ﬁller cap in

extra SCA.

d Maintenance Manual, “Reﬁll

dinstallanewﬁller cap. If the gasket

s stamped on the face of the ﬁller cap. If

i02151646

Driven Equipment - Check

Refer to the OEM speciﬁcations for more information on the fol the driven equipment:

Inspecti

•

Adjustment

•

Lubrication

•

Other mai

•

Perform any maintenance for the driven equipment which is r

lowing maintenance recommendations for

ntenance recommendations

ecommended by the OEM.

i01936072

Engine - Clean

Personal injury or death can result from high voltage.

Moisture ca n 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”

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

Periodic cleaning of the engine is recommended. Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following beneﬁts:

Easy detection of ﬂuid leaks

•

Maximum heat transfer characteristics

•

Ease of maintenance

•

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

NOTICE

Page 68

68 SEBU8311-01

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

i02736653

Engine Air Cleaner Elemen t (Dual Element

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

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

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air can split the material of the air cleaner element. Unﬁltered ai engine wear. Your Perkins dealer has the proper air cleaner elements for your application. Consult your Perkins dea

r will drastically accelerate internal

ler for the correct air cleaner element.

) - C lean/Replace

NOTICE

Dual Element Ai

The dual element air cleaner contains a primary air cleaner el element. The primary air cleaner element can be used up to six times if the element is properly cleaned and inspecte should be replaced at least one time per year. This replacement should be performed regardless of the number of cle

The secondary air cleaner element is not serviceable or washable. should be removed and discarded for every three cleanings of the primary air cleaner element. When the engine i dusty or dirty, air cleaner elements may require more frequent replacement.

ement and a secondary air cleaner

d. The primary air cleaner element

anings.

The secondary air cleaner element

s operating in environments that are

r Cleaners

Check the precleaner (if equipped) daily for

•

accumulati and debris, as needed.

Operating c

•

require more frequent service of the air cleaner element.

The air cleaner element may be cleaned up to

•

six times if the element is properly cleaned and inspected

The air cleaner element should be replaced at least

•

one time pe performed regardless of the number of cleanings.

Replace th clean air cleaner elements. Before installation, the air cleaner elements should be thoroughly checked for tears the gasket or the seal of the air cleaner element for damage. Maintain a supply of suitable air cleaner elements

on of dirt and debris. Remove any dirt

onditions (dust, dirt and debris) may

r year. This replacement should be

e dirty paper air cleaner elements with

and/or holes in the ﬁlter material. Inspect

for replacement purposes.

tion 38

Illustra

(1) C over (2) Primary air c leaner element (3) Secondary air cleaner element (4) Turbocharger air inlet

1. Remove the cover. Remove the primary air cleaner element.

2. The secondary air cleaner element should be removed and discarded for every three cleanings of the pri

Note: Refer to “Cleaning the Primary Air Cleaner Elements

3. Cover the turbocharger air inlet with tape in order to keep di

4. Clean the inside of the air cleaner cover and body with a cl

5. Remove the tape for the turbocharger air inlet. Install primary air cleaner element that is new or cleaned.

mary air cleaner element.

”.

rt out.

ean, dry cloth.

the secondary air cleaner element. Install a

g00736431

6. Install

7. Reset the air cleaner service indicator.

the air cleaner cover.

Page 69

SEBU8311-01 69

This document has been printed from SPI². Not for Resale

Maintenance Section

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

Cleaning the Primary Air Cleaner Elements

NOTICE Perkins recommends certiﬁed air ﬁlter cleaning services that are available at Perkins dealers. The Perkins cleaning process uses proven procedures to assure consistent quality and sufﬁcient ﬁlter life.

Observe the following guidelines if you attempt to clean the ﬁlter element:

Do not tap or strike the ﬁlter element in order to remove dust.

Do not wash the ﬁlter element.

Use low pressure compressed air in order to remove the dust from the ﬁlter element. Air pressure must not exceed 207 kPa (30 psi). Direct the air ﬂow up the pleats and down the pleats from the inside of the ﬁlter element. Take extreme care in order to avoid damage to the pleats.

Do not use air ﬁlters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to engine components.

Pressurized Ai

Pressurized air can be used to clean primary air cleaner eleme than two times. Pressurized air will not remove deposits of carbon and oil. Use ﬁltered, dry air with a maximum pres

Illustration 39

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

nts that have not been cleaned more

sure of 207 kPa (30 psi).

g00281692

The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected. When the primary air cleaner element is cleaned, check for rips or tears in the ﬁlter material. The primary air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.

Use clean primary air cleaner elements while dirty elements are being cleaned.

NOTICE Do not clean the air cleaner elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine damage could result.

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

There are two common methods that are used to clean primary air cleaner elements:

Aim the hose so that the air ﬂows inside the element along the length of the ﬁlter in order to help prevent damage to the paper pleats. Do not aim the stream of air directly at the primary air cleaner element. Dirt could be forced further into the pleats.

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

Vacuum Cleaning

Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil.

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

Pressurized air

•

Vacuum cleaning

•

Page 70

70 SEBU8311-01

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

Inspecting the

Primary Air Cleaner

Elements

Illustration 40

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

lean, dry primary air cleaner element.

tate the primary air cleaner element.

hat may show through the ﬁlter material. If it

ement that has the same part number.

g00281693

Do not use paint protective covering for storage. An air ﬂow restriction may result. To protect against dirt and damage, wrap the primary ai Inhibited (VCI) paper.

Place the pri for storage. For identiﬁcation, mark the outside of the box and mark the primary air cleaner element. Include the f

Date of cleaning

•

Number of cleanings

•

Store the box

, a waterproof cover, or plastic as a

r cleaner elements in Volatile Corrosion

mary air cleaner element into a box

ollowing information:

in a dry location.

i02152042

Engine Air Cleaner Element (Single Element) Inspect/Replace

Refer to Operation and Maintenance Manual, “Engine Air Cleaner Service Indicator-Inspect”.

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

nd/or holes in the ﬁlter material. Do not

er elements.

Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes inspection will not be used, the primary air cleaner element can be store

Illustration 41

d for future use.

g00281694

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

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

A wide variety of air cleaners may be installed for use with this engine. Consult the OEM information for the correct procedure to replace the air cleaner.

.Neverruntheenginewithadamagedair

ses premature wear and damage to engine

NOTICE

i02335405

Engine Air C lean er Service Indicator - Inspect

Some engines may be equipped with a different service indicator.

Page 71

SEBU8311-01 71

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Maintenance Section

Engine Air Precleaner - Check/Clean

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

The service indicator may be mounted on the air cleaner ele

e equipped with a differential gauge

ed before the air cleaner element and

differential rises. If your engine is

ner service indicator.

ment or in a remote location.

Engine Air Precleaner Check/Clean

on 43

Illustrati

Typical engine air precleaner

(1) Wing nut (2) C over (3) Body

i02927289

g01453058

Illustration 42

Typical service indicator

Observe the service indicator. The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur:

The yellow diaphragm enters the red zone.

•

The red piston locks in the visible position.

•

g00103777

Test the Service Indicator

Service indicators are important instruments.

Check for ease of resetting. The service indicator

•

should reset in less than three pushes.

Check the movement of the yellow core when

•

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

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

Remove wing n accumulation of dirt and debris in body (3). Clean the body, if necessary.

After cleaning the precleaner, install cover (2) and wing nut (1).

Note: When the engine is operated in dusty applications, more frequent cleaning is required.

ut (1) and cover (2). Check for an

i02657627

Engine Crankcase Breather Replace

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

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Maintenance Section Engine Mounts - Inspect

6. Install a new di

aphragm and plate (4) for the breather assembly into the cavity (7) of the valve mechanism cover or the spacer (5) for turbocharged

engines.

7. Install a new spring (3).

8. Install the breather cover (2) and the four screws

(1). Tighten the screws.

i02323089

Engine Mounts - Inspect

Note: The engine mounts may not have been

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

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

Incorrect mounting of the engine

•

Illustration 44

Typical ex

(1) Screws for the breather cover (2) Breather cover (3) Spring (4) Diaphrag m and plate (5) Spacer for turbocharged engines only (6) Joint for turbocharged engines on ly (7) Cavity (8) Vent hole

ample

g01335247

1. Loosen the screws (1) and remove the breather cover (2) from the valve mechanism cover.

2. Remove the spring (3). Remove the diaphragm and plate (4).

3. For turbocharged engines, remove the spacer (5) and the joint (6).

4. Clean the vent hole (8) and the cavity (7) in the valve mechanism cover.

NOTICE

Make sure t

hat the components of the breather assembly are installed correctly. Engine damage may occur if the breather assembly is not working correctly.

Deterioration of the engine mounts

•

Loose engine mounts

•

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

i02153660

Engine Oil Level - Check

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

5. For turbocharged engines, install a new joint (6)

and the spacer (5).

Illustration 45

(Y) “ADD” mark. (X) “FULL” mark.

g00110310

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SEBU8311-01 73

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Maintenance Section

Engine Oil and Filter - Change

NOTICE

Perform this ma

1. Maintain the oil level between “ADD” mark (Y) and

“FULL” mark (X) the crankcase above “FULL” mark (X).

Operating you “FULL” mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into t acteristics and could result in the loss of power.

2. Remove the oil ﬁller cap and add oil, if necessary.

Clean the oil ﬁller cap. Install the oil ﬁller cap.

intenance with the engine stopped.

on oil level gauge (1). Do not ﬁll

NOTICE

r engine when the oil level is above the

he oil reduces the oil’s lubricating char-

i02610655

Engine Oil and Filter - Change

Hot oil and hot components can cause personal injury. Do n contact the skin.

ot allow hot oil or hot components to

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 Oil

After the engine has been run at the normal operating temperature, stop the engine. Use one of the following me

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

•

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

If the engine is not equipped with a drain valve,

•

removetheoildrainpluginordertoallowtheoilto drain. After should be cleaned and installed.

thods to drain the engine crankcase oil:

nob counterclockwise in order to drain

the oil has drained, the oil drain plug

Replace the Oil Filter

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

Dispose of all ﬂuids according to local regulations and mandates.

NOTICE Keep all par

Contaminants may cause rapid wear and shortened component

Do not drain the oil when the engine is cold. As the oil cools, suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed with the draining cold oil. Drain the crankcase with the engine stopped. Drain the crankcase with the oil warm. This draining method allows the waste particles that are suspended in the oil to be drained correctly.

ts clean from contaminants.

life.

1. Remove the oil ﬁlter with a suitable tool.

Note: The following actions can be carried out as

part of the preventive maintenance program.

2. Cut the oil ﬁlter open with a suitable tool. Break apart the pleats and inspect the oil ﬁlter for metal debris. An excessive amount of metal debris in the oil ﬁlter may indicate early wear or a pending failure.

Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil ﬁlter element. Ferrous metals may indicate wear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on the aluminum parts, brass parts or bronze parts of the engine. Parts that may be affected include the following items: main bearings, rod bearings, turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is not uncommon to ﬁnd small amounts of debris in the oil ﬁlter. Consult your Perkins dealer or your Perkins distributor in order to arrange for a further analysis if an excessive amount of debris is found in the oil ﬁlter.

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Maintenance Section Engine Valve Lash - Inspect/Adjust

NOTICE To prevent cran gine with the fuel OFF. This will ﬁll the oil ﬁlters before starting the engine. Do not crank the engine for more than 30 second

2. Start the engine and run the engine at “LOW

IDLE” for two minutes. Perform this procedure in order to ensur oil and that the oil ﬁlters are ﬁlled. Inspect the oil ﬁlter for oil leaks.

3. Stop the engine and allow the oil to drain back to

thesumpforaminimumoftenminutes.

kshaft bearing damage, crank the en-

e that the lubrication system has

Illustration 46

(1) Oil c ooler (2) Ad apter (3) Oil ﬁlter

Note: The oil cooler (1) and the adapter (2) are installed on engines that have a turbocharger.

3. Clean the sealing surface of the cylinder block or the oil cooler (1).

4. Apply clean engine oil to the new oil ﬁlter seal (3).

NOTICE Do not ﬁll the oil ﬁlters with oil before installing them. This oil would not be ﬁltered and could be contaminated. Contaminated oil can cause accelerated wear to engine components.

5. Install the oil ﬁlter. Tighten the oil ﬁlter by hand. Do

not overtighten the oil ﬁlter.

g01334593

Fill the Engine Crankcase

1. Remove the oil ﬁller cap. Refer to the Operation

and Maintenance Manual for more information on lubricant speciﬁcations. Fill the crankcase with the correct amount of oil. Refer to the Operation and Maintenance Manual for more information on reﬁll capacities.

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

Illustration 47

Typical example

4. Remove the oil level gauge in order to check the oil level. Maintain the oil level between the “MIN” and “MAX” marks on the oil level gauge.

g00986928

i02676023

Engine Valve Lash Inspect/Adjust

This maintenance is recommended by Perkins as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life. The maintenance for the valve lash is important in order to keep the engine compliant.

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

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

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Maintenance Section

Fuel Injector - Test/Change

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

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

Ensure that the engine is stopped before measuring the valve lash. The engine valve lash can be inspected and adjusted when the temperature of the engine is hot or cold.

Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash - Inspect/Adjust” for more information.

i02154268

Fuel Injector - Test/Change

Regular mainte recommended by Perkins. The fuel injectors must be removed and tested by an authorized agent. The fuel injector incorrect tools can damage the nozzle. The fuel injectors should be renewed only if a fault with the fuel injecto indicate that new fuel injectors are needed are listed below:

The engine will not start or the engine is difﬁcult

•

to start.

Not enough power

•

Theenginemi

•

High fuel consumption

•

Black exhaust smoke

•

The engine k

•

engine.

Excessive e

•

For further information on the removal and the installati Disassembly and Assembly manual.

on of the fuel injectors, refer to the

nance of the fuel injectors is

s should not be cleaned as cleaning with

rs occurs. Some of the problems that may

sﬁres or the engine runs erratically.

nocks or there is vibration in the

ngine temperature

Fuel leaked cal components can cause a ﬁre.

Make sure that you wear eye protection at all times during testing. When fuel injection nozzles are tested, test ﬂuids travel through the oriﬁces of the nozzle tip with high pressure. Under this amount of pressure, the test ﬂuid can pierce the skin and cause serious injury to the operator. Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension.

Do not allo clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fu

or spilled onto hot surfaces or electri-

NOTICE

w dirt to enter the fuel system. Thoroughly

el system component.

For further refer to the Testing and Adjusting manual.

information on the testing of fuel injectors,

Identiﬁcation of a suspect Fuel Injector

Work carefully around a n engine that is running. Engine parts that are hot, or pa rts that are moving, can cause

If your skin comes into contact with high pressure fuel, obtain medical assistence immediately.

If a fuel injector is suspected of operating outside of normal par technician. The suspect fuel injector should be taken to an authorised agent for inspection.

personal injury.

NOTICE

ameters it should be removed by a qualiﬁed

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Maintenance Section Fuel System - Prime

Operate the eng identify the faulty fuel injector. Individually loosen and tighten the union nut for the high pressure pipe to each fuel in morethanhalfaturn.Therewillbelittleeffectonthe engine speed when the union nut to the faulty fuel injector is l

Consult your authorized Perkins dealer or your Perkins dist

Fuel System -

Care must be t during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect t opening any compartment or disassembling any component containing ﬂuids.

Dispose of all ﬂuids according to local regulations and mandates.

Use the foll system:

If air enter from the fuel system before the engine can be started. Air can enter the fuel system when the following

The fuel tank is empty or the fuel tank has been

•

partially

events occur:

ine at a fast idle speed in order to

jector. Do not loosen the union nut

oosened.

ributor for further assistance.

i02596360

Prime

NOTICE

aken to ensure that ﬂuids are contained

he ﬂuid with suitable containers before

owing procedure in order to prime the fuel

s the fuel system, the air must be purged

drained.

Primary ﬁlter

Ensure that the air is removed from the primary ﬁlter before you prime the fuel ﬁ lters. Refer to illustration

48.

Illustration 48

This ﬁlter may not be installed on the engine.

(1) Vent screws

g01316878

Fuel ﬁlters

There are three types of fuel ﬁlter that may be installed on the engine.

Element

•

Canister

•

The low pressure fuel lines are disconnected.

•

A leak exists in the low pressure fuel system.

•

The fuel ﬁl

•

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.

ter is replaced.

NOTICE

Spin-on ﬁlter with fuel priming pump

•

Page 77

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Maintenance Section

Fuel System - Prime

Illustration 49

Element

(2) Fuel v alve (3) Vent screw

Illustration 50

Canister

(4) Vent

screw

g01327360

g013273

Illustration 51

Spin-on ﬁlter with fuel priming pump

(5) Vent screw

g01327363

Vent screw (3) is installed on the ﬁlter that has an element. Vent screw (4) is installed on the fuel ﬁlter that has a canister. Vent screw (5) is installed on the spin-on ﬁlter.

Priming the system

Ensure that the air is removed from the primary ﬁlter. Loosen vent screws (1). Refer to illustration 48. Operate the priming pump. When fuel free from air ﬂows from the vent screw tighten the vent screw.

Note: Some fuel system will use gravity in order to prime the primary fuel ﬁlter. If gravity is used ensure that the fuel tank is full and that all stop valves in the fuel line are open.

There is four different types of systems that can be installed on the engine in order to prime the fuel system. Refer to illustration 52.

Hand priming pump

•

In-line hand priming pump

•

Electrical priming pump

•

Transfer pump that is operated by the starting

•

motor

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Maintenance Section Fuel System - Prime

Illustration 52

(6) Hand p (7) In-li

Illustration 53

(10) Connector bolt (11) Fuel return line (12) Connector bolt

riming pump

ne priming pump

(8) Elect (9) Fuel t

rical priming pump

ransfer pump

g01301853

g01304597

Hand Priming Pump 6

1. Ensure that fuel valve (2) for the fuel ﬁlter that

has an element is in the ON position. Refer to

In order to identify the hand priming pump, refer to

illustration 49.

illustration 52.

2. Loosen vent screw (3 4 or 5) on the fuel ﬁlter.

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SEBU8311-01 79

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Maintenance Section

Fuel System - Prime

3. Operate hand pr from air ﬂows from the vent screw tighten the vent screw.

4. Loosen connection (10 or 12) at the fuel injection pump. Refer to illustration 53.

Note: Fuel return line (11) may need to be removed in order to prime the fuel system.

5. Operate the hand priming pump. When fuel free from air ﬂows from the connections tighten the connecting b

6. The engine should now be able to start. Operate the starting

Note: Do not operate the starting motor for more than 15 secon seconds, stop and wait for 30 seconds before trying again.

iming pump (6). When fuel free

olt.

motor in order to start the engine.

ds. If the engine does not start after 15

In-line Priming Pump 7

In order to i illustration 52.

1. Ensure that has an element is in the ON position. Refer to illustration 49.

2. Loosen vent screw (3 4 or 5) on the fuel ﬁlter.

dentify the in-line priming pump, refer to

fuel valve (2) for the fuel ﬁlter that

1. Ensure that fue has an element is in the ON position. Refer to illustration 49.

2. Loosen vent screw (3 4 or 5) on the fuel ﬁlter.

3. Operate elect

free from air ﬂows from the vent screw tighten the vent screw. Switch off the electrical priming pump.

4. Loosen connection (10 or 12) at the fuel injection pump. Refer to illustration 53.

Note: Fuel return line (11) may need to be removed in order to prime the fuel system.

5. Operate the in-line priming pump. When fuel free from air ﬂows from the connections tighten the connecting b

6. The engine should now be able to start. Operate the startin

Note: Do not operate the starting motor for more than 15 seco seconds, stop and wait for 30 seconds before trying again.

l valve (2) for the fuel ﬁlter that

rical priming pump (8). When fuel

olt.

g motor in order to start the engine.

nds. If the engine does not start after 15

Fuel Transfer Pump 9

In order to i illustration 52.

dentify the fuel transfer pump, refer to

3. Operate infrom air ﬂows from the vent screw tighten the vent screw.

4. Loosen connection (10 or 12) at the fuel injection pump. Refer to illustration 53.

Note: Fuel return line (11) may need to be removed in order to prime the fuel system.

5. Operate the in-line priming pump. When fuel free from air ﬂows from the connections tighten the connecti

6. The engine should now be able to start. Operate the start

Note: Do not operate the starting motor for more than 15 se seconds, stop and wait for 30 seconds before trying again.

line priming pump (7). When fuel free

ng bolt.

ing motor in order to start the engine.

conds. If the engine does not start after 15

Electrical Priming Pump 8

In order to illustration 52.

to identify the electrical priming pump, refer

Note: In ord operate the starting motor. Do not operate the starting motor for more than 15 seconds. After 15 seconds, stop and wa starting motor.

1. Ensure tha has an element is in the ON position. Refer to illustration 49.

2. Loosen vent screw (3 4 or 5) on the fuel ﬁlter.

3. Operate f

from air ﬂows from the vent screw tighten the vent screw. Stop the fuel transfer pump.

4. Loosen connection (10 or 12) at the fuel injection pump. Refer to illustration 53.

Note: Fuel return line (11) may need to be removed in order to prime the fuel system.

5. Operate the fuel transfer pump. When fuel free from air ﬂows from the connections tighten the connect

6. The engine should now be able to start. Operate the star

er to use the transfer pump, you must

it for 30 seconds before operating the

t fuel valve (2) for the fuel ﬁlter that

uel transfer pump (9). When fuel free

ing bolt. Stop the transfer pump.

ting motor in order to start the engine.

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Maintenance Section Fuel System Filter - Replace

Note: Do not ope than 15 seconds. If the engine does not start after 15 seconds, stop and wait for 30 seconds before trying again.

rate the starting motor for more

i02608681

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 Do not allow d clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel

irt to enter the fuel system. Thoroughly

system component.

Illustration 54

Typical example

2. Clean the outside of the fuel ﬁlter assembly (1).

g01307792

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 Filter with Canister

1. Close the fuel supply valve.

3. Remove setscrew (2).

4. Remove the canister (3). Ensure that any ﬂuid is

drained into a suitable container.

Illustration 55

Typical example

g01334877

5. Assemble the following items: seals (8), seal (7), canister (3), and bowl (10). Place washer (5) and seal (6) on setscrew (2).

6. Fasten the assembly to the fuel ﬁlter base with setscrew (2).

Page 81

SEBU8311-01 81

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Maintenance Section

Fuel System Filter - Replace

The fuel system new ﬁlter is installed. Refer to this Operation and Maintenance Manual, “Fuel System - Prime”.

willneedtobeprimedafterthe

Fuel Filter with Element

1. Close the fuel supply valve (1).

Illustration 56

Typical exam p le

2. Clean the outside of the fuel ﬁlter assembly.

3. Loosen the locking ring (2).

4. Removethecasing(3)fortheﬁlter and the

element. Ensure that any ﬂuid is drained into a suitable container.

g01334893

Illustration 57

Typical example

Note: Do not ﬁll the fuel ﬁlter with fuel. The fuel will not be ﬁltered and the fuel could be contaminated. Contaminated fuel can damage your fuel system.

5. Assemble the following items: seal (5), ﬁlter element (6) and casing (3).

6. Install the assembled items to the ﬁlter base (4).

7. Install the locking ring (2) to the ﬁlter head. Rotate

the locking ring in order to lock the assembly.

The fuel system will need to be primed after the new ﬁlter is installed. Refer to this Operation and Maintenance Manual, “Fuel System - Prime”.

g01334895

Fuel F ilter with Priming Pump

1. Close the fuel supply valve.

2. Clean the outside of the fuel ﬁlter assembly.

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Maintenance Section Fuel System Primary Filter/Water Separator - Drain

NOTICE The water separ tor separates water from the fuel. The engine should never be allowed to run with the water separator more than half full

ator is not a ﬁlter. The water separa-

. Engine damage may result.

Illustration 58

Typical exam p le

3. By using a suitable tool, remove spin-on ﬁlter (1). Ensure that any ﬂuid is drained into a suitable container.

Note: Do not ﬁll the fuel ﬁlter with fuel. The fuel will not be ﬁltered and the fuel could be contaminated. Contaminated fuel can damage your fuel system.

4. Install the new spin-on ﬁlter. Tighten the spin-on ﬁlter by hand.

The fuel system will need to be primed after the new ﬁlter is installed. Refer to this Operation and Maintenance Manual, “Fuel System - Prime”.

g01306131

i02627223

Fuel System Primary Filter/Water Separator - Drain

Illustration 59

Typical example

1. Open drain (1). Catch the draining ﬂuidina suitable container. Dispose of the drained ﬂuid correctly.

2. Close drain (1).

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

g01316965

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Maintenance Section

Fuel Tank Water and Sediment - Drain

i02335436

Fuel Tank Water and Sediment

-Drain

Dispose of all ﬂuids according to local regulations and mandates.

Fuel Tank

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

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

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

Some fuel tanks 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 inte

•

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 reﬁ lled or moved recently, a settle before ﬁlling the engine fuel tank. Internal bafﬂes in the bulk storage tank will also help trap sediment. F storage tank helps to ensure the quality of the fuel. When possible, water separators should be used.

rvals

llow adequate time for the sediment to

iltering fuel that is pumped from the

i02813964

Hoses and Clamps Inspect/Replace

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.

Inspect a following conditions:

Cracking

•

Softness

•

Loose clamps

•

Replace h loose clamps.

Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause ﬁres. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque. Do not clip any other item to the high pressure lines.

Check for the following conditions:

ll hoses for leaks that are caused by the

oses that are cracked or soft. Tighten any

NOTICE

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Maintenance Section Radiator - Clean

End ﬁttings tha

•

Outer covering that is chafed or cut

•

Exposed wire that is used for reinforcement

•

Outer coverin

•

Flexible part of the hose that is kinked or crushed

•

Armoring that is embedded in the outer covering

•

A constant tor 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. Harde 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

•

s depend on the following factors:

t are damaged or leaking

g that is ballooning locally

quehoseclampcanbeusedinplace

ning of the hoses will cause hose

2. Loosen the cool order to relieve any pressure. Remove the cooling system ﬁller cap.

Note: Drain the coolant into a suitable, clean container. The coolant can be reused.

3. Drain the coolant from the cooling system to a level that is below the hose that is being replaced.

4. Removethehoseclamps.

5. Disconnect t

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: For the c

Maintenance Manual, “Fluid Recommendations”.

8. Reﬁll the coo information for further information on reﬁlling the cooling system.

9. Clean the cooling system ﬁller cap. Inspect the cooling system ﬁller cap’s seals. Replace the cooling sys Install the cooling system ﬁller cap.

ing system ﬁller cap slowly in

he old hose.

orrect coolant, see this Operation and

ling system. Refer to the OEM

tem ﬁller cap if the seals are damaged.

Anticipated

•

Anticipated expansion and contraction of the

•

ﬁttings

Replace the

Refer to the OEM information for further information on removing

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

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

1. Stop the e

expansion and contraction of the hose

Hoses and the Clamps

and replacing fuel hoses (if equipped).

ot usually supplied by Perkins. The

formation on the coolant system and the

. To open the cooling system ﬁller cap,

cap slowly in order to relieve the pres-

ngine. Allow the engine to cool.

10. Start the en leaks.

gine. Inspect the cooling system for

i02335774

Radiator - Clean

The radiator is not usually supplied by Perkins. The following t for the radiator. Refer to the OEM information for further information on cleaning the radiator.

ext describes a typical cleaning procedure

Note: Adjust the frequency of cleaning according to the effects of the operating environment.

Page 85

SEBU8311-01 85

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Maintenance Section

Severe Service Application - Check

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

Personal inj

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

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

Pressurized loose debris. Direct the air in the opposite direction to the fan’s air ﬂow. Hold the nozzle approximately 6mm(0.25inc move the air nozzle in a direction that is parallel with the radiator tube assembly. This will remove debris that is betw

Pressurized water may also be used for cleaning. The maximum 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. Cl with detergent and hot water. Thoroughly rinse the core with clean water.

If the radiator is blocked internally, refer to the OEM Manual for information regarding ﬂushing the cooling system.

After cleaning the radiator, start the engine. Allow the engin ﬁve minutes. Accelerate the engine to high idle. This will help in the removal of debris and the drying of the core and then stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat t

.Slowlyreducetheenginespeedtolowidle

iator for these items: Damaged ﬁns,

ury can result from air pressure.

. When using pressure air, wear a pro-

ressure at the nozzle must be less

air is the preferred method for removing

h) away from the radiator ﬁns. Slowly

een the tubes.

water pressure for cleaning purposes

ean both sides of the core. Wash the core

e to operate at low idle speed for three to

he cleaning, if necessary.

i02335775

Severe Service Application Check

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

Performance

•

and fuel consumption

Fuel quality

•

Operational Altitude

•

Maintenance intervals

•

Oil selectio

•

Coolant type and maintenance

•

Environmental qualities

•

Installatio

•

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 parameters.

Severe serv wear. Engines that operate under severe conditions may need more frequent maintenance intervals in order to ens full service life.

Due to indiv to identify all of the factors which can contribute to severe service operation. Consult your Perkins dealer or y maintenance that is necessary for the engine.

ns maintains standards for the following

such as power range, speed range,

n and maintenance

the engine is operating within the deﬁned

ice operation can accelerate component

ure maximum reliability and retention of

idual applications, it is not possible

our Perkins distributor for the unique

Inspect the ﬁns for damage. Bent ﬁns may be opened with a “c Welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.

omb”. Inspect these items for good condition:

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

ing environment, incorrect operating

ion.

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Maintenance Section Starting Motor - Inspect

Environmental Factors

Ambient temper

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

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

Buildup – Co chemicals and salt can damage some components.

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

Incorrect

Extended operation at low idle

•

Frequent hot shutdowns

•

Operating

•

Operating at excessive speeds

•

Operating outside the intended application

•

atures – The engine may be

n be damaged by carbon buildup if

rmance.

peration in an environment that is

e can be very difﬁcult. The buildup can

mpounds, elements, corrosive

roblems can arise when the engine is

ade.

Operating Procedures

at excessive loads

Check the start the electrical connections and clean the electrical connections. Refer to the Systems Operation, Testing and Adjusting Test” for more information on the checking procedure and for speciﬁcations or consult your Perkins dealer or your Perki

ing motor for correct operation. Check

Manual, “Electric Starting System -

ns distributor for assistance.

i02184788

Turbocharger - Insp ect (If Equipped)

A regular visual inspection of the turbocharger is recommended. Any fumes from the crankcase are ﬁltered through the air inlet system. Therefore, by-products from oil and from combustion can collect in the turbocharger compressor housing. Over time, this buildup can contribute to loss of engine power, increased black smoke and overall loss of engine efﬁciency.

If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to the turbocharger compressor wheel can cause additional damage to the pistons, the valves, and the cylinder head.

NOTICE Turbocharger bearing failures can cause large quantities of oil to enter the air intake and exhaust systems. Loss of engine lubricant can result in serious engine damage.

Incorrect Maintenance Procedures

Extending

•

Failure to use recommended fuel, lubricants and

•

coolant/a

Starting M

Perkins recommends a scheduled inspection of the starting motor. If the starting motor fails, the engine may not st

the maintenance intervals

ntifreeze

i02177969

otor - Inspect

art in an emergency situation.

Minor leakage of oil into a turbocharger under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occured.

When a turbocharger bearing failure is accompanied by a signiﬁcant engine performance loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until the turbocharger is renewed.

A visual inspection of the turbocharger can minimize unscheduled downtime. A visual inspection of the turbocharger can also reduce the chance for potential damage to other engine parts.

Removal and Installation

Note: The turbochargers that are supplied are

nonserviceable.

Page 87

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Maintenance Section

Walk-Around Inspection

For options reg replacement, consult your Perkins dealer or your Perkins distributor. Refer to the Disassembly and Assembly Manu Turbocharger - Install” for further information.

arding the removal, installation, and

al, “Turbocharger - Remove and

Inspecting

NOTICE The compress not be removed from the turbocharger for cleaning.

The actuator housing. If the actuator linkage is moved or disturbed the engine may not comply with emmissions legislation.

1. Remove the pipe from the turbocharger exhaust

outlet and remove the air intake pipe to the turbocharg presence of oil. Clean the interior of the pipes in order to prevent dirt from entering during reassembly

2. Check for the presence of oil. If oil is leaking from

the back si possibility of a failed turbocharger oil seal.

or housing for the turbocharger must

linkage is connected to the compressor

er. Visually inspect the piping for the

de of the compressor wheel, there is a

The guards must

•

damaged guards or replace missing guards.

Wipe all caps a

•

serviced in order to reduce the chance of system contamination.

For any type of ﬂuid. If leaking is observed, ﬁnd the source and correct the leak. If leaking is suspected, check the ﬂuid levels more often th 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 this Operation and Maintenance Manual, “Engine - Clean” for more information.

Ensure that the cooling system hoses are correctly

•

clamped and that the cooling system hoses are tight. Check for leaks. Check the condition of all pipes.

Inspect the water pump for coolant leaks.

•

be in the correct place. Repair

nd plugs before the engine is

NOTICE

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

an recommended until the leak is found

NOTICE

The presen engine operation at low idle. The presence of oil mayalsobetheresultofarestrictionoftheline for the int the turbocharger to slobber.

3. Inspect t

outlet for corrosion.

4. Fasten th

pipe to the turbocharger housing.

ce of oil may be the result of extended

ake air (clogged air ﬁlters), which causes

he bore of the housing of the turbine

e air intake pipe and the exhaust outlet

i02177973

Walk-Around Inspection

Inspect the Engine for Leaks and for Loose Connections

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

For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections and trash buildup. Make repairs, as needed:

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 the water pump seal. For the removal of the water pump and the installation of water pump and/or seal, refer to the Disassembly and Assembly Manual, “Water Pump - Remove and Install” for more information or 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 fuel system for leaks. Look for loose

•

fuel line clamps and/or tie-wraps.

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.

Inspect the alternator belts and any accessory

•

drive belts for cracks, breaks or other damage.

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Maintenance Section Water Pump - Inspect

Belts for multi matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belt the new belt could cause the belt to break.

Drain the wat

•

tank on a daily basis in order to ensure that only clean fuel enters the fuel system.

Inspect the wiring and the wiring harnesses for

•

loose connections and for worn wires or frayed wires.

Inspect the ground strap for a good connection and

•

for good cond

Disconnect any battery chargers that are not

•

protected a motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintena

Check the condition of the gauges. Replace any

•

gauges tha can not be calibrated.

ple groove pulleys must be replaced as

s are stretched. The additional load on

er and the sediment from the fuel

ition.

gainst the current drain of the starting

ncefreebattery.

t are cracked. Replace any gauge that

i01907756

Water Pump - Inspect

A failed water pump may cause severe engine overheati conditions:

Cracks in t

•

Apistonseizure

•

Other potential damage to the engine

•

Note: The w coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and parts

Visually inspect the water pump for leaks. Renew the water is an excessive leakage of coolant. Refer to the Disassembly and Assembly Manual, “Water Pump

- Remove assembly procedure.

ng problems that could result in the following

he cylinder head

ater pump seal is lubricated by the

contract.

pump seal or the water pump if there

and Install” for the disassembly and

Page 89

SEBU8311-01 89

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Warranty Section

Warranty Information

Warranty Section

Warranty Information

i01903596

Emissions Warranty Information

This engine may be certiﬁed to comply with exhaust emission standards and gaseous emission standards that are pre manufacture, and this engine may be covered by an Emissions Warranty. Consult your authorized Perkins dealer or yo to determine if your engine is emissions certiﬁed and if your engine is subject to an Emissions Warranty.

scribed by the law at the time of

ur authorized Perkins distributor in order

Page 90

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Index Section

Index

After Startin

After Stopping Engine............................................ 34

Alternator - Inspe ct ................................................ 59

Alternator an

Adjustment ......................................................... 59

Inspection........................................................... 59

Alternator and

Battery - Replace ................................................... 60

Battery Electr

Battery or Battery Cable - Disconnect ................... 61

Before Starting Engine ..................................... 11, 30

Burn Preventio

Batteries............................................................... 8

Coolant................................................................. 8

Oils....................................................................... 8

Cold Weather Operation ........................................ 35

Hints for Cold W

Idling the Engine ................................................ 36

Recommendations for Coolant Warm Up .......... 36

Recommendation

Viscosity of the Engine Lubrication Oil............... 35

Cooling System Coolant (Commercial Heavy-Duty) -

Change ................................................................ 62

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

Fill ...................................................................... 63

Flush .................................................................. 62

Cooling System Coolant (ELC) - Change.............. 63

Drain .................................................................. 64

Fill ...................................................................... 64

Flush .................................................................. 64

Cooling System Coolant Extender (ELC) - Add..... 65

Cooling System Co

Engines With a Coolant Recovery Tank............. 65

Engines Without a Coolant Recovery Tank........ 66

Cooling System Sup

(SCA) - Test/Add.................................................. 66

Add the SCA, If Necessary ................................ 66

Test for SCA Conce

Crushing Prevention and Cutting Prevention ........ 10

Driven Equipment

g Engine ............................................. 32

d Fan Belts - Inspect/Adjust .............. 59

Fan Belts - Replace ....................... 60

olyte Level - Check .......................... 61

n....................................................... 8

eather Operation ...................... 35

s for the Coolant .................... 35

olant Level - Check ................. 65

plemental Coolant Additive

ntration ............................... 66

- Check..................................... 67

Electrical Sy

Grounding Practices .......................................... 12

Emergency Stopping ............................................. 34

Emissions Cer

Emissions Warranty Information............................ 89

Engine - Clean....................................................... 67

Engine Air Clea

Clean/Replace ..................................................... 68

Cleaning the Primary Air Cleaner Elements ...... 69

Servicing the A Engine Air Cleaner Element (Single Element) -

Inspect/Replace ................................................... 70

Engine Air Clea

Test the Service Indicator................................... 71

Engine Air Precleaner - Check/Clean .................... 71

Engine Crankca

Engine Description ................................................ 16

Engine Speciﬁcations......................................... 17

Engine Identiﬁc

Engine Lifting......................................................... 25

Engine Mounts - Inspect........................................ 72

Engine Oil and Fi

Drain the Engine Oil ........................................... 73

Fill the Engine Crankcase .................................. 74

Replace the Oil Fi

Engine Oil Level - Check ....................................... 72

Engine Operation................................................... 33

Engine Starting ................................................. 11,

Engine Stopping ............................................... 11, 34

Engine Storage...................................................... 25

Cooling System.................................................. 26

Exhaust System ................................................. 27

General Items .................................................... 27

Induction System ............................................... 2

Lubrication System ............................................ 25

Engine Valve Lash - Inspect/Adjust ....................... 74

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

Fire Prevention and Explosion Prevention .............. 8

Fire Extinguisher ................................................ 1

Lines, Tubes and Hoses .................................... 10

Fluid Recommendations........................................ 41

Engine Oil .......................................................... 42

General Lubricant Information ........................... 41

Fluid Recommendations (Coolant Speciﬁcations).. 45

ELC Cooling System M

General Coolant Information.............................. 45

Fluid Recommendations (Fuel Speciﬁ

Diesel Fuel Charact

Diesel Fuel Requirements.................................. 50

General Information ........................................... 50

stem ................................................... 12

tiﬁcation Film .................................. 24

ner Element (Dual Element) -

ir Cleaner Elements ................... 68

ner Service Indicator - Inspect...... 70

se Breather - Replace .................. 71

ation .............................................. 23

lter - Change .............................. 73

lter ......................................... 73

aintenance .................... 48

cation) ........ 50

eristics ................................ 52

Page 91

SEBU8311-01 91

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Index Section

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

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

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

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

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

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

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

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

Fuel and the Effect from Cold Weather ................. 37

Fuel Conservati

Fuel Injector - Test/Change ................................... 75

Identiﬁcation of a suspect Fuel Injector.............. 75

Fuel Related Comp

Fuel Filters ......................................................... 38

Fuel Heaters ...................................................... 38

Fuel Tanks.......................................................... 38

Fuel Shutoff ........................................................... 29

Fuel System - Prime .............................................. 76

Fuel ﬁlters .......................................................... 76

Primary ﬁlter....................................................... 76

Priming the system ............................................ 77

Fuel System Filter

Fuel Filter with Canister ..................................... 80

Fuel Filter with Element ..................................... 81

Fuel Filter with Pr Fuel System Primary Filter/Water Separator -

Drain .................................................................... 82

Fuel Tank Water and

Drain the Water and the Sediment..................... 83

Fuel Storage Tanks............................................ 83

Fuel Tank ........................................................... 83

Gauges and Indicators .......................................... 28

General Hazard Inf

Containing Fluid Spillage ..................................... 8

Fluid Penetration.................................................. 7

Pressure Air and Wat

on Practices.................................. 33

onents in Cold Weather .......... 38

- Replace ................................. 80

iming Pump ............................ 81

Sediment - Drain ................. 83

ormation .................................... 7

er........................................ 7

Maintenance Se

Model View Illustrations......................................... 13

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

Operation Section.................................................. 25

Product Ident

Product Information Section .................................. 13

Radiator - Cle

Reference Numbers .............................................. 23

Record for Reference......................................... 23

Reﬁll Capacit

Cooling System.................................................. 40

Lubrication System ............................................ 39

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

(A) Universal Warning .......................................... 5

Safety Section

Serial Number Plate .............................................. 23

Severe Service Application - Check ...................... 85

Environmental F

Incorrect Maintenance Procedures .................... 86

Incorrect Operating Procedures......................... 86

Starting Motor -

Starting the Engine ................................................ 30

Starting with Jump Start Cables ............................ 31

Stopping the Eng

ction ............................................. 39

iﬁcation Information .......................... 23

an .................................................... 84

ies ..................................................... 39

......................................................... 5

actors ....................................... 86

Inspect ......................................... 86

ine .............................................. 34

Hoses and Clamps - Inspect/Replace ................... 83

Replace the Hoses an

Important Safety Information ................................... 2

Lifting and Storage ................................................ 25

Maintenance Inter

d the Clamps .................. 84

val Schedule ............................. 58

Table of Contents..................................................... 3

Turbocharger - I

Inspecting........................................................... 87

Removal and Installation.................................... 86

Walk-Around Inspection ........................................ 87

Inspect the Engine for Leaks and for Loose

Connections ..................................................... 87

Warranty Information ............................................. 89

Warranty S ection ................................................. .. 89

Water Pump - Inspe

nspect (If Equipped)..................... 86

ct............................................ 88

Page 92

92 SEBU8311-01

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Index Section

Page 93

Product and Dealer Information

This document has been printed from SPI². Not for Resale

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 94

This document has been printed from SPI². Not for Resale

Perkins Engine 402D, 403D, 404D Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual