Perkins Engine 800D Service Manual
Operation and
Maintenance
Manual
SEBU8324-00
August 2007
800D Series Industrial Engines
(Engine)
UK
UL (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
SEBU8324 3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 5
General Hazard Information ................................... 7
Burn Prevention ...................................................... 8
Fire Prevention and Explosion Prevention .............. 9
Crushing Prevention and Cutting Prevention ......... 11
Mounting and Dismounting .................................... 11
Before Starting Eng ine ........................................... 11
Engine Starting ..................................................... 12
Engine Stopping ................................................... 12
Electrical System .................................................. 12
Index Section
Index ..................................................................... 72
Product Information Section
Model Views ......................................................... 14
Product Identification Information ........................ 19
Operation Section
Lifting and Storage .................. .............................. 22
Gauges and Indicators .......................................... 24
Features and Controls .......................................... 25
Engine Starting ..................................................... 26
Engine Operation .................................................. 29
Engine Stopping ................................................... 31
Cold Weather Operation ....................................... 32
Maintenance Section
Refill Capacities .................................................... 36
Maintenance Interval Schedule ............................ 49
Warranty Section
Warranty Information ............................................ 71
4 SEBU8324
Foreword
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.
n
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.
SEBU8324 5
Safety Section
Safety Messages
Safety Section
i02697668
Safety Messages
There may be s
an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Ple
signs.
Ensure that a
the warning signs or replace the warning signs if
the words cannot be read or if the pictures are not
visible. Wh
cloth, water, and soap. Do not use solvent, gasoline,
or other harsh chemicals to clean the warning signs.
Solvents,
the adhesive that secures the warning signs. The
warning signs that are loosened could drop off of
the engine
Replace any damaged warning signs or missing
warning si
of the engine that is replaced, install a new warning
sign on the replacement part. Any Perkins dealer
or any Per
signs.
Do not wor
engine unless the instructions and warnings in the
Operation and Maintenance Manual are understood.
Proper c
the instructions or failure to heed the warnings could
result in injury or in death.
are is your responsibility. Failure to follow
everal specific warning signs on
ase become familiar with all warning
ll of the warning signs are legible. Clean
en the warning signs are cleaned, use a
gasoline, or harsh chemicals could loosen
.
gns. If a warning sign is attached to a part
kins distributor can provide new warning
k on the engine and do not operate the
The warning labels that may be found on the engine
are illustrated and described.
6 SEBU8324
Safety Section
Safety Messages
Illustration 1
Typical example
(1) Universal Warning (2) Warning label for the Starting Aid
g01353473
SEBU8324 7
Safety Section
General Hazard Information
Universal Warning (1)
The universal warning label (1) is located on the top
of the valve mechanism cover.
g01273386
Do not operate or work on this engine unless you
have read and understand the instructions and
warnings in the Operation and Maintenance Manual. Fail ure to follow the instructions or heed the
warnings could result in injury or de ath.
i02328435
General Hazard Information
Illustration 2
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before you s
ervice the equipment or before you
repair the equipment.
g00104545
Starting Aid (2)
The warning label for the starting aid (2) is located on
the side of the air inlet manifold.
g01273387
Do not use aerosol types of starting aids such as
ether.
personal injury.
Such use could result in an explosion and
Illustration 3
g0070202
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.
Never put maintenance fluids into glass containers.
Drain al
l liquids into a suitable container.
0
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care.
8 SEBU8324
Safety Section
Burn Prevention
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
The maximum air pressure for cleaning purposes
must be belo
water pressure for cleaning purposes must be below
275kPa(40psi).
ury.
d water to the body could result in personal
rized air and/or water is used for
ive face shield.
w 205 kPa (30 psi). The maximum
Illustration 4
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
g00687600
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Make provision to collect the fluid with a
suitable container before any compartment is opened
or before any component is disassembled.
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.
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.
i01480768
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
SEBU8324 9
Safety Section
Fire Prevention and Explosion 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.
Ensure that th e filler cap is cool before removing the
filler cap. The fi ller cap must be cool enough to touch
withabarehand.Removethefiller cap slowly in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
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 Preventio n and Exp losio n
Prevent
ion
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
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,
88
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.
hly with a nonflammable solvent prior to
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
.
s away from unauthorized persons. Store
ammable materials.
a seal failure. Exhaust shields must be
ld on lines or tanks that contain flammable
Illust
ration 5
g00704000
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.
ust be kept in good condition. All electrical
e loose or frayed before you operate the
ommended gauge. Do not bypass any fuses
10 SEBU8324
Safety Section
Fire Prevention and Explosion Prevention
Arcing or spark
ing could cause a fire. Secure
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
on. The hoses must be correctly routed.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended
torque. Leaks can cause fires.
Oil filters and fuel filters must be correctly installed.
The filter hou
sings must be tightened to the correct
torque.
Illustration 7
g00704135
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Illustration 6
g00704059
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
ahydrometer.
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
Donotbendhighpressurelines.Donotstrikehigh
pressure lines. Do not install any lines that are bent
or damaged. Do not clip any other items to the high
pressure lines.
SEBU8324 11
Safety Section
Crushing Prevention and Cutting Prevention
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
i02235492
Mounting and Dismounting
Inspect the ste
before mounting the engine. Keep these items clean
and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the en
Face the engine in order to mount the engine or
dismount the
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
controls as h
Do not stand on components which cannot support
your weight
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to rais
ps, the handholds, and the work area
gine, and do not jump off the engine.
engine. Maintain a three-point contact
andholds.
. Use an adequate ladder or use a work
e and lower tools or supplies.
i01805780
i01359666
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 properly 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
Before Starting Engine
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up o
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/o
Overspeed shutdown should occur automatically.
If automa
emergency stop button in order to cut the fuel and/or
air to the engine.
Inspect the engine for potential hazards.
Before st
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights w
f an engine that has been serviced, make
r fuel supply to the engine.
tic shutdown does not occur, press the
arting the engine, ensure that no one is on,
ork properly, if equipped.
12 SEBU8324
Safety Section
Engine Starting
All protective
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that
around the parts carefully.
Do not bypass
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are
engine damage.
See the Servi
adjustments.
guards and all protective covers must
is caused by parts in rotation, work
the automatic shutoff circuits. Do not
also provided in order to help prevent
ce Manual for repairs and for
i01933350
Engine Starting
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operator’s compartment or
from the engine start switch.
Note: The engin
device for cold starting for normal conditions of
operation. If the engine will be operated in very cold
conditions, t
required. Normally, the engine will be equipped with
the correct type of starting aid for your region of
operation.
The 800 Series engine is equipped with a glow plug
starting aid
intake air in order to improve starting.
e is equipped with an automatic
henanextracoldstartingaidmaybe
in each individual cylinder that heats the
i01032808
Engine Stopping
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 NOT use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop the
engine if an overspeed condition occurs. This may be
accomplished by shutting off the fuel supply and/or
the air supply to the engine.
i021766
Electrical System
68
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, 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 operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Never di
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases th
To help prevent sparks from igniting combustible
gases t
negative “−” jump start cable should be connected
last from the external power source to the negative
“−”ter
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
befor
electrical wires before the engine is started. See
the Operation and Maintenance Manual for specific
start
sconnect any charging unit circuit or battery
at are produced by some batteries to ignite.
hat are produced by some batteries, the
minal of the starting motor. If the starting motor
e the engine is started. Repair all frayed
ing instructions.
SEBU8324 13
Safety Section
Electrical System
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.
14 SEBU8324
Product Information Section
Model Views
Product Information
Section
Model Views
i02697676
Model View Illustrations
Illustration 8
Left side view of a naturally aspirated engine
This view is shown without one of the fuel injectors for clarity.
(1) Fan
(2) Fuel injector
(3) Glow plug
(4) Oil filler cap
(5) L ifting eye
(6) Water drain plug or drain valve
(7) Oil level gauge
(8) Flywheel housing
(9) Oil filter
(10) R elief valve
g01264543
(11) Oil drain plug
(12) Oil pressure switch
(13) Fuel injection pump
(14) Oil F iller
(15) Water pump
SEBU8324 15
Product Information Section
Model Views
Illustration 9
(16) O il filler cap
(17) Lifting eye
(18) T hermostat
(19) Alte rnator
(20) V-Belt
(21) Crankshaft vibration damper
g01264517
(22) Starting motor
(23) Exhaust manifold
16 SEBU8324
Product Information Section
Model Views
Illustration 10
Left s ide view of turbocharged engine
(1) Glow plug
(2) Inlet manifold
(3) Fuel injector
(4) C rankcase breather
(5) Water dr ain plug or drain valve
(6) Oil level gauge
(7) Fuel injection pump
(8) Oil filter
(9) Relief valve
(10) Oil drain plug
g01353575
(11) Oil filler
(12) V -belt
(13) O il cooler
(14) F an
SEBU8324 17
Product Information Section
Model Views
Illustration 11
Right side view of turbocharged engine
(15) Turbocharger
(16) F ront lifting eye
(17) Coolant switch
(18) A lternator
(19) Starting motor
(20) O il pan
(21) Flywheel housing
(22) Flywheel
g01353864
(23) Exhaust manifold
(24) Re a r lifting eye
(25) Top oil filler
18 SEBU8324
Product Information Section
Model Views
i02700110
Engine Description
Table 1
Naturally Aspirated Specifications
Type
Number of Cylinders
Bore
Stroke 120 mm (4.72 inch)
Aspiration Naturally Aspirated
Compression ratio 22:1
Displacement 3.33 L (203 in3)
Firing Order
Rotation that is viewed
from the flywheel
Valve Lash Setting (Inlet) 0.25 mm (0.0098 inch)
Valve Lash Setting
(Exhaust)
Table 2
Turbocharged Specifications
Type
Number of Cylinders 4 In-Line
Bore 94 mm (3.70 inch)
Stroke 120 mm (4.72 inch)
Aspiration Turbocharged
Compressio
(73.7 hp)
Compression ratio 62 kW
(83 hp)
Displacement 3.33 L (203 in3)
Firing Order 1-3-4-2
Rotation that is viewed
from the flywheel
Valve Lash Setting (Inlet) 0.25 mm (0.0098 inch)
Valve Lash Setting
(Exhaust)
nratio55kW
Four Stroke Cycle
4 In-Line
94 mm (3.70 inch)
1-3-4-2
Counterclockwise
0.25 mm (0.0098 inch)
Four Stroke Cycle
20.5:1
19.5:1
Counterclockwise
0.25 mm (0.0098 inch)
Water temperat
•
ure regulators which regulate the
engine coolant temperature
Gear-driven o
•
Oil cooler
•
il pump (gear type)
The engine lubricating oil is supplied by a gear
type pump. The engine lubricating oil is cooled and
the engine lub
ricating oil is filtered. Bypass valves
provide unrestricted flow of lubrication oil to the
engine parts when oil viscosity is high. Bypass valves
canalsoprov
ide unrestricted flow of lubrication oil
to the engine parts if the oil cooler should become
plugged or if the oil filter element should become
plugged.
Engine efficiency, efficiency of emission controls, and
engine perf
ormance depend on adherence to proper
operation and maintenance recommendations.
Engine performance and efficiency also depend on
the use of r
ecommended fuels, lubrication oils, and
coolants. Refer to the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
informati
Engine Ser
on on maintenance items.
vice Life
Engine efficiency and maximum utilization of engine
performan
ce depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants and
lubrican
ts. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
Expected
engine life is generally predicted by the
average power that is demanded. The average power
that is demanded is based on fuel consumption of
the engi
ne over a period of time. Reduced hours of
operation at full throttle and/or operating at reduced
throttle settings result in a lower average power
demand.
Reduced hours of operation will increase
the length of operating time before an engine
overhaul is required.
Engine Cooling and Lubrication
The cooling system consists of the following
components:
Gear-driven centrifugal water pump
•
SEBU8324 19
Product Information Section
Product Identification Information
Product Identification
Information
Plate Locations and Film
Locations
i02741945
Serial Number Plate (1)
The engine serial number plate is located on the right
side of the cylinder block at the rear of the engine.
Illustration 13
Serial number plate
g01094203
i02164876
Reference Numbers
Illustration 12
Location of serial number plate
Perkins engines are identified by an engine serial
number.
An example of an engine number is UL*****J000001L.
UL
__________________________________________Type of engine
____________________ The list number for the engine
*****
______________________________________________ Built in Japan
J
g01372283
Information for the following items may be needed to
order parts
Record the information in the appropriate space.
Make a copy of this list for a record. Keep the
informatio
Record for
Engine Model _ ______________________________________________
Engine Serial number _____________________________________
Engine Low
Engine Full Load rpm ________ _____________________________
Primary Fuel Filter _________________________________________
Water Sepa
Secondary Fuel Filter Element ____________________ ______
Lubrication Oil Filter Element ___________________________
. Locate the information for your engine.
n for future reference.
Reference
Idle rpm
rator Element
______________________________________
________________________________
000001
L
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.
___________________________ Engine Serial Number
_____________________________________ Year of Manufacture
Auxiliary
Total Lubrication System Capacity _____________ ________
Total Cooling System Capacity _________________________
Air Cleane
Oil Filter Element
r Element
_______________________________
_______________________________________
20 SEBU8324
Product Information Section
Product Identification Information
Fan Drive Belt _
_____________________________________________
Alternator Belt ______________________________________________
i02742745
Emissions Certification Film
Illustration 14
Typical exa mple
EPA Environmental Protection Agency
•
CARB California Air Resources Board
•
EEC European Economic Community
•
g01372645
The emissions label (1) is located on the top of the
valve mechanism cover. The 800D industrial engine
complies with worldwide emissions standards and
with EPA/CARB off road Tier iii engines. The 800D
industrial engine complies with EEC off road mobile
machinery that is at stage III.
SEBU8324 21
Product Information Section
Product Identification Information
Illustration 15
Typical ex
ample
g01381011
22 SEBU8324
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
i02513632
Product Lifting
Illustration 16
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle
between the supporting members and the object becomes less than 90 degrees.
g00103219
i02744521
Product Storage
If the engine is
lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
walls. Rust on
engine wear and a reduction in engine service life.
Perkins are no
occur when an engine is in storage after a period in
service.
Your Perkins distributor can assist in preparing the
engine for extended storage periods.
If an engine is out of operation and if use of the
engine is not planned for more than one month, a
complete pr
To help prevent excessive engine wear and corrosion
to the engin
1. Completely clean the outside of the engine.
2. Ensure that the vehicle is on level ground.
3. Drain the fu
thesystemwithpreservativefuel.1772204
POWERPARTLay-Up1canbemixedwith
the normal f
preservative fuel.
not started for a month or longer the
the cylinder walls will cause increased
t responsible for damage which may
otection procedure is recommended.
e, use the following guidelines:
el system completely and refill
uel in order to change the fuel into
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other . The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting the fixtures in order to
obtain proper balance and safety.
ToremovetheengineONLY,usetheliftingeyesthat
are on the engine.
Lifting eyes are designed and installed for specific
engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Perkins dealer for information regarding fixtures for
proper engine lifting.
If preserv
can be filled with normal fuel. This fuel must be
discarded at the end of the storage period together
with the fu
Personal
contact with hot coolant or with steam can cause
severe burns. Allow cooling system components
to cool be
4. Drain and refill the cooling system. Refer to this
Operatio
System coolant (Commercial Heavy Duty Change or Cooling System coolant (ELC) Change”
refilling the cooling system.
5. Operate
normal operating temperature. If necessary,
perform minor adjustments. Check for any leaks.
Stop the
system and from the cooling, lubrication or air
systems.
ative fuel is not available, the fuel system
el filter elements.
injury can result from hot coolant. Any
fore the cooling system is drained.
n and Maintenance Manual, “Cooling
for information on draining, flushing and
the engine until the engine reaches
engine. Repair any leaks from the fuel
SEBU8324 23
Operation Section
Lifting and Storage
6. Drain the lubri
Renew the canister(s) of the lubricating oil filter.
Fill the oil pan to the Full Mark on the engine oil
level gauge with new, clean lubricating oil. Add
1762811 POWER
order to protect the engine against corrosion. If
1762811 POWERPART Lay-Up 2 is not available,
use a preserv
instead of the lubricating oil. If a preservative is
used, t his must be drained completely at the end
of the storag
refilled to the correct level with normal lubricating
oil.
7. Operate the engine in order to circulate engine oil.
8. Disconnect
in a fully charged condition. Protect the terminals
against corrosion. 1734115 POWERP ART
Lay-Up3ca
battery into safe storage.
9. If equippe
element. Seal the end of the breather pipe.
cating oil from the oil pan.
PART Lay-Up 2 to the oil in
ative of the correct specification
e period and the oil pan must be
the battery. Ensure that the battery is
nbeusedontheterminals.Putthe
d, replace the crankcase breather
17. In order to prev
of the engine, spray the engine with 1734115
POWERPART Lay-Up 3. Do not spray the area
inside the alt
ent corrosion to the outside
ernator.
10. Remove the
1762811 POWERPARTLay-Up2aroundthe
rocker shaft assembly.
11. Remove the glow plugs. Slowly rotate the
crankshaft. By checking the valves, position the
piston at B
Lay-Up 2 for two seconds into the cylinder bore.
This procedure must be carried out on each
cylinder
12. Install the glow plugs. Install the valve mechanism
cover.
13. Remove the pipes that are installed between
the air fi
Spray 1762811 POWERPART Lay-Up 2 into
the turbocharger. The duration of the spray is
printed
with waterproof tape .
14. Remove t
the turbocharger. Spray 1762811 POWERPART
Lay-Up 2 into the turbocharger. The duration of
the spr
turbocharger with waterproof tape.
valve mechanism cover. Spray
DC. Spray 1762811 POWERPART
.
lter assembly and the turbocharger.
on the container. Seal the turbocharger
he exhaust pipe from the output side of
ay is printed on the container. Seal the
15. Seal th
with waterproof tape .
16. Remove
belt into storage.
e vent of the fuel tank or the fuel filler cap
the alternator drive belt and put the drive
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