珀金斯Perkins1103D-33(T)(TA)操作保养（英文）

Operation and

Maintenance

Manual

1103D Industrial Engine

XK (Engine)

XL (Engine)

XM (Engine)

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Important Safety Information

Most  accidents    tha t involve  produc  t  op eration,  ma intena nc e and   repair   are  caus  ed  by  failure  to

ob serve  basic   safety   rules  or  precautions  .  An accident    can   often  be  avoided   by  recog nizing  pote ntially

ha za rdous  situations   before   an  accident    oc curs . A person    mus t be  alert   to pote ntial  ha za rds.  This

person   should   also  ha ve  the  ne cessary   training,  skills  and   tools  to perform   the se  func tions 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.

Sa fety precautions     and  warning s  are   provided   in this  ma nua l and   on  the  produc t.  If the se  ha za rd

warning s  are  not  he eded,   bod ily injury  or death   could   oc cur to  you  or to  othe r persons  .

The  ha za rds are   identified   by  the  “Safety  Alert  Symb ol”  and  followed  by  a  “Signa l  Word” suc h  as

“DANGER”, “WARNING”  or “CAUTION”.  The Sa fety  Alert  “WARNING” label  is  shown   below.

The  me aning  of  this safety   alert   symb ol is  as  follows:

Attention! Become Alert! Your Safety is  Involved.

The  me ssage   tha t appears     und er the   warning  explains    the  ha za rd and   can  be   either  written  or

pictorially   presente  d.

Op erations  tha t  ma y caus e  produc  t dama  ge  are  identified   by  “NOTICE” labels   on  the  produc  t and   in

this  pub lication.

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  informa tion, specifications   ,  and  illustrations   in  this  pub lication  are   on the  basis    of informa tion tha t

was  available    at  the  time  tha t the  pub lication   was  written.   The  specifications   , torque  s,  pressure  s,

me asure me nts , adjustme  nts , illustrations ,  and  othe r  items  can  cha  ng e at  any  time.  These  cha ng es  can

affect   the  service   tha t is given   to the  produc  t.  Ob tain the  comp  lete  and  mos t current   informa tion before

you  start any   job. Pe  rkins  dealers   or   Pe rkins  distributors     ha ve  the  mos t current   informa tion  available.

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

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Table of Contents

Table of Contents

Index Section

Index .....................................................................  73

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

Safety Section

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

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

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

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

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

Mounting and Dismounting ................................... 10

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

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

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

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

Product Information Section

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

Product Identification Information  ........................  16

Operation Section

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

Gauges and Indicators .......................................... 22

Features and Controls ..........................................  23

Engine Starting .....................................................  24

Engine Operation .................................................. 27

Engine Stopping ...................................................  28

Cold Weather Operation ....................................... 29

Maintenance Section

Refill Capacities ....................................................  33

Maintenance Interval Schedule ............................  46

Warranty Section

Warranty Information ............................................  72

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Foreword

Foreword

Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance

Interval Schedule. The actual operating environment

of the engine also governs the Maintenance Interval

Schedule. Therefore, under extremely  severe,

dusty, wet or freezing cold  operating conditions,

more frequent lubrication and maintenance than is

specified in the Maintenance Interval Schedule may

be necessary.

Literature Information

This manual contains safety, operation instructions,

lubrication and maintenance information.  This

manual should be stored in or near the engine area

in a literature holder or literature storage area. Read,

study and keep it with  the literature and engine

information.

The maintenance schedule items are organized for

a preventive maintenance management program. If

the preventive maintenance program is followed, a

periodic tune-up is not required. The implementation

of a preventive maintenance management program

should minimize operating  costs through cost

avoidances resulting from reductions in unscheduled

downtime and failures.

English is the primary  language for all Perkins

publications. The English used facilitates translation

and consistency.

Some photographs or illustrations in this  manual

show details or attachments that may be different

from your engine. Guards and  covers may have

been removed for illustrative purposes. Continuing

improvement and advancement of product design

may have caused changes to your engine which are

not included in this manual. Whenever a question

arises regarding your engine, or this manual, please

consult with your Perkins dealer  or your Perkins

distributor for the latest available information.

Maintenance Intervals

Perform maintenance on items  at multiples of

the original requirement. We recommend that the

maintenance schedules be reproduced and displayed

near the engine as a convenient reminder. We also

recommend that a maintenance record be maintained

as part of the engine’s permanent record.

Safety

Your authorized Perkins dealer  or your Perkins

distributor can assist  you in adjusting  your

maintenance schedule to meet the needs of  your

operating environment.

This safety section lists basic safety  precautions.

In addition, this  section identifies hazardous,

warning situations. Read and understand the basic

precautions listed in  the safety section before

operating or performing lubrication, maintenance and

repair on this product.

Overhaul

Major engine overhaul details are not  covered in

the Operation and Maintenance Manual  except

for the interval and the maintenance items  in that

interval. Major repairs should only be carried out by

Perkins authorized personnel. Your Perkins dealer

or your Perkins distributor offers a variety of options

regarding overhaul programs. If you  experience

a major engine failure, there  are also numerous

after failure overhaul options available. Consult with

your Perkins dealer or your Perkins distributor for

information regarding these options.

Operation

Operating techniques outlined in this manual  are

basic. They assist with developing  the skills and

techniques required to operate the  engine more

efficiently and economically. Skill and techniques

develop as the operator gains  knowledge of the

engine and its capabilities.

The operation section is a reference for operators.

Photographs and illustrations guide the  operator

through procedures of inspecting, starting, operating

and stopping the engine. This section also includes a

discussion of electronic diagnostic information.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents

are known to the State of California to cause cancer,

birth defects, and other reproductive harm. Battery

posts, terminals and related accessories contain lead

and lead compounds. Wash hands after handling.

Maintenance

The maintenance section is a guide to engine care.

The illustrated, step-by-step instructions are grouped

by service hours and/or calendar time maintenance

intervals. Items in the maintenance schedule  are

referenced to detailed instructions that follow.

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Safety Section

Safety Messages

Safety Section

i02811420

Safety Messages

There may be several specific warning signs on your

engine. The exact location and a description of the

warning signs are reviewed in this section. Please

become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean

the warning signs or replace the  warning signs if

the words cannot be read or if the illustrations are

not visible. Use a cloth, water, and  soap to clean

the warning signs. Do not use solvents, gasoline, or

other harsh chemicals. Solvents, gasoline, or harsh

chemicals could loosen the adhesive that secures the

warning signs. The warning signs that are loosened

could drop off of the engine.

Replace any warning sign  that is damaged or

missing. If a warning sign is attached to a part of the

engine that is replaced, install a new warning sign on

the replacement part. Your Perkins dealer or your

distributor can provide new warning signs.

(1) Universal Warning

Do not operate or work on this equipment unless

you  have read  and understand  the  instructions

and warnings  in the Operation  and Maintenance

Manuals.  Failure  to   follow  the  instructions  or

heed the  warnings could result  in serious injury

or death.

g01154807

Illustration 1

Typical example

The Universal Warning label (2) is located on the rear

end of the inlet manifold cover. Refer to illustration 2.

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SEBU8352

Safety Section

General Hazard Information

g01431463

i02328435

Illustration 2

(1) Ether Warning Label

(2) Universal warning

(2) Ether

General Hazard Information

Do not use aerosol types of starting aids such as

ether. Such use could  result in an explosion and

personal injury.

g00104545

Illustration 4

Attach a “Do Not Operate” warning tag or a similar

warning tag to the start  switch or to the controls

before you service the equipment  or before you

repair the equipment.

g01154809

Illustration 3

Typical example

The ether warning label (1) is located on the  front

end of the inlet manifold cover. Refer to illustration 2.

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Safety Section

General Hazard Information

When pressurized air and/or  water is used for

cleaning, wear protective clothing, protective shoes,

and eye protection. Eye protection includes goggles

or a protective face shield.

The maximum air pressure for cleaning purposes

must be below 205 kPa  (30 psi). The maximum

water pressure for cleaning purposes must be below

275 kPa (40 psi).

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long

after the engine has been stopped. The pressure can

cause hydraulic fluid or items such as pipe plugs to

escape rapidly if the pressure is not relieved correctly.

g00702020

Illustration 5

Wear a hard hat,  protective glasses, and other

protective equipment, as required.

Do not remove any hydraulic components or parts

until pressure has been relieved or personal injury

may occur. Do not  disassemble any hydraulic

components or parts until pressure has been relieved

or personal injury may occur.  Refer to the OEM

information for any procedures that are required to

relieve the hydraulic pressure.

Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

Make sure that all protective guards and all covers

are secured in place on the engine.

Keep the engine free from foreign material. Remove

debris, oil, tools, and other items from the deck, from

walkways, and from steps.

Never put maintenance fluids into glass containers.

Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Report all necessary repairs.

Do not allow  unauthorized personnel on the

equipment.

g00687600

Illustration 6

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.

Ensure that the power supply is disconnected before

you work on the bus bar or the glow plugs.

Perform maintenance on  the engine with the

equipment in the servicing position.  Refer to the

OEM information for the procedure for placing the

equipment in the servicing position.

Containing Fluid Spillage

Pressure Air and Water

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.

Pressurized air and/or water  can cause debris

and/or hot water to be blown out. This could result in

personal injury.

The direct  application of pressurized air  or

pressurized water to the body could result in personal

injury.

•  Only use the tools that are suitable for collecting

fluids and equipment that is suitable for collecting

fluids.

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SEBU8352

Safety Section

Burn Prevention

•  Only use the tools that are suitable for containing

fluids and equipment that is suitable for containing

fluids.

i02813488

Fire Prevention and Explosion

Prevention

Obey all local regulations for the disposal of liquids.

i02143195

Burn Prevention

Do not touch any  part of an operating engine.

Allow the engine to cool before any  maintenance

is performed on the engine.  Relieve all pressure

in the air system, in  the hydraulic system, in the

lubrication system, in the fuel  system, or in the

cooling system before any lines, fittings or related

items are disconnected.

Coolant

g00704000

Illustration 7

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.

All fuels, most lubricants, and some coolant mixtures

are flammable.

Flammable fluids that are leaking or spilled onto hot

surfaces or onto electrical components can cause

a fire. Fire may cause personal injury and property

damage.

Any contact with hot coolant or with steam can cause

severe burns. Allow cooling system components to

cool before the cooling system is drained.

A flash fire may result if the covers  for the engine

crankcase are removed within fifteen minutes after

an emergency shutdown.

Check the coolant level after the engine has stopped

and the engine has been allowed to cool.

Ensure that the filler cap is cool before removing the

filler cap. The filler cap must be cool enough to touch

with a bare hand. Remove the filler  cap slowly in

order to relieve pressure.

Determine whether the engine will be operated in an

environment that allows combustible gases to be

drawn into the air inlet system. These gases could

cause the engine to overspeed.  Personal injury,

property damage, or engine damage could result.

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contact

the skin, the eyes, or the mouth.

If the application involves the presence of combustible

gases, consult your Perkins  dealer and/or your

Perkins distributor for additional information about

suitable protection devices.

Oils

Remove all flammable combustible materials  or

conductive materials such as fuel, oil, and debris from

the engine. Do not allow any flammable combustible

materials or conductive materials to accumulate on

the engine.

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

Store fuels and lubricants  in correctly marked

containers away from unauthorized persons. Store

oily rags and any flammable materials in protective

containers. Do not smoke in areas that are used for

storing flammable materials.

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.

Do not expose the engine to any flame.

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Safety Section

Fire Prevention and Explosion Prevention

Exhaust shields (if equipped) protect hot exhaust

components from oil or fuel spray in case of a line,

a tube, or a seal failure. Exhaust  shields must be

installed correctly.

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.

Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines or tanks that contain

flammable fluid. Clean any  such lines or tanks

thoroughly with a nonflammable  solvent prior to

welding or flame cutting.

Wiring must be kept in good condition. All electrical

wires must be correctly routed and securely attached.

Check all electrical wires daily.  Repair any wires

that are loose or  frayed before you operate the

engine. Clean all electrical connections and tighten

all electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than

the recommended gauge. Do not bypass any fuses

and/or circuit breakers.

Arcing or sparking  could cause a fire. Secure

connections, recommended wiring, and correctly

maintained battery cables will help to prevent arcing

or sparking.

g00704135

Illustration 9

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.

Inspect all  lines and hoses for  wear or for

deterioration. 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.

Never check the battery charge by placing a metal

object across the terminal posts. Use a voltmeter or

a hydrometer.

Oil filters and fuel filters must be correctly installed.

The filter housings must be tightened to the correct

torque.

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.

g00704059

Illustration 8

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SEBU8352

Safety Section

Crushing Prevention and Cutting Prevention

Lines, Tubes and Hoses

When objects are struck, wear protective glasses in

order to avoid injury to the eyes.

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.

Chips or other debris may fly off objects when objects

are struck. Before objects are struck, ensure that no

one will be injured by flying debris.

Repair any lines that are loose or damaged. Leaks

can cause fires. Consult your Perkins dealer or your

Perkins distributor for repair or for replacement parts.

i01372247

Mounting and Dismounting

Check lines, tubes and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or

cardboard to check for leaks. Tighten all connections

to the recommended torque.

Inspect the steps, the handholds, and the work area

before mounting the engine. Keep these items clean

and keep these items in good repair.

Replace the parts if any of the following conditions

are present:

Mount the engine and dismount the engine only at

locations that have steps and/or handholds. Do not

climb on the engine, and do not jump off the engine.

•  End fittings are damaged or leaking.

•  Outer coverings are chafed or cut.

•  Wires are exposed.

Face the engine in order to  mount the engine or

dismount the engine. Maintain a three-point contact

with the steps and handholds. Use two feet and one

hand or use one foot and two hands. Do not use any

controls as handholds.

•  Outer coverings are ballooning.

•  Flexible part of the hoses are kinked.

•  Outer covers have embedded armoring.

•  End fittings are displaced.

Do not stand on components which cannot support

your weight. Use an adequate ladder or use a work

platform. Secure the climbing equipment so that the

equipment will not move.

Do not carry tools or supplies when you mount the

engine or when you dismount the engine. Use a hand

line to raise and lower tools or supplies.

Make sure that all clamps, guards, and heat shields

are installed correctly. During engine operation, this

will help to prevent vibration, rubbing against other

parts, and excessive heat.

i02813489

Before Starting Engine

i02143194

Crushing Prevention  and

Cutting Prevention

Before the initial start-up of an engine that is new,

serviced or repaired, make provision  to shut the

engine off, in order to stop an overspeed. This may

be accomplished by shutting off the air and/or fuel

supply to the engine.

Support the component correctly when work beneath

the component is performed.

Overspeed shutdown should occur automatically for

engines that are controlled electronically. If automatic

shutdown does not occur, press the emergency stop

button in order to cut the fuel and/or air to the engine.

Unless other maintenance instructions are provided,

never attempt adjustments while  the engine is

running.

Stay clear of all rotating  parts and of all moving

parts. Leave the guards in place until maintenance

is performed. After the maintenance is performed,

reinstall the guards.

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 of personnel.

Keep objects away from moving fan blades. The fan

blades will throw objects or cut objects.

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Safety Section

Engine Starting

If equipped, ensure that the lighting system for the

engine is suitable for the conditions. Ensure that all

lights work correctly, if equipped.

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.

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.

Note: The engine is equipped with  an automatic

device for cold starting  for normal conditions of

operation. If the engine will be operated in very cold

conditions, then an extra cold starting aid may  be

required. Normally, the engine will be equipped with

the correct type of starting  aid for your region of

operation.

Do not bypass the automatic shutoff circuits. Do not

disable the automatic shutoff circuits. The circuits are

provided in order to help prevent personal injury. The

circuits are also provided in order to  help prevent

engine damage.

The engines are equipped with a glow plug starting

aid in each individual cylinder that heats the intake

air in order to improve starting.

See the  Service Manual for repairs  and for

adjustments.

i01928905

i02207232

Engine Stopping

Engine Starting

Stop the engine according  to the procedure in

the Operation and Maintenance Manual, “Engine

Stopping (Operation Section)” in  order to avoid

overheating of the engine and accelerated wear of

the engine components.

Do not use aerosol types of starting aids such as

ether. Such use could  result in an explosion and

personal injury.

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.

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.

Stop the engine if an overspeed condition occurs

during the initial start-up of a new engine or an engine

that has been overhauled. This may be accomplished

by shutting off the fuel supply to the engine and/or

shutting off the air supply to the engine.

Start the engine from the operator’s compartment or

from the engine start switch.

i02176668

Electrical System

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.

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 ensure that the jacket water heater (if equipped)

and/or the lube oil heater (if equipped)  is working

correctly, check the water temperature gauge and the

oil temperature gauge during the heater operation.

To help prevent sparks from igniting  combustible

gases that are produced by  some batteries, the

negative “−” jump start cable should be connected

last from the external power source to the negative

“−” terminal of the starting motor. If the starting motor

is not equipped with a negative “−” terminal, connect

the jump start cable to the engine block.

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SEBU8352

Safety Section

Electrical System

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

i02869409

Model View Illustrations

1103D Engine Model Views

g01439632

Illustration 10

Typical example

(1) Front lifting eye

(4) Fuel filter

(8) Oil filter (horizontal installation)

(2) Water temperature regulator  housing

(horizontal outlet)

(3) Fuel priming pump

(5) Breather tube

(6) Water pump

(7) Starting motor

(9) Crankshaft pulley

(10) Oil pan

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SEBU8352

Product Information Section

Model Views

g01434352

Illustration 11

Typical example

(11) Inlet manifold adapter

(12) Top cover

(13) Exhaust manifold

(14) Turbocharger (if equipped)

(15) Turbocharger oil supply (if equipped)

(16) Turbocharger oil return (if equipped)

(17) Rear lifting eye

(18) Flywheel housing

(19) Flywheel

Engine Specifications

i02813494

Engine Description

Note: The front end of the engine is  opposite the

flywheel end of the engine. The  left and the right

sides of the engine are determined from the flywheel

end. The number 1 cylinder is the front cylinder.

Perkins Engines are designed  for the following

applications: machine  and industrial mobile

equipment. The engines are available in the following

types of aspiration:

•  Turbocharged aftercooled

•  Turbocharged

•  Naturally aspirated

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SEBU8352

15

Product Information Section

Model Views

The engine lubricating oil is supplied to the engine

by a gear-driven pump. The engine lubricating oil

is cooled and the engine lubricating oil  is filtered.

Bypass valves provide unrestricted flow of lubrication

oil to the engine parts when  oil viscosity is high.

Bypass valves can also provide 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 performance depend on adherence to proper

operation and maintenance recommendations.

Engine performance and efficiency also depend on

the use of recommended fuels, lubrication oils, and

coolants. Refer to the Operation and Maintenance

Manual, “Maintenance Interval Schedule” for more

information on maintenance items.

g01222531

Illustration 12

A typical example of the layout of the valves

(A) Inlet valves

(B) Exhaust valves

Engine Service Life

Table 1

1103D Industrial Engine Specifications

Engine efficiency and maximum utilization of engine

performance depend on the adherence to proper

operation and maintenance recommendations. In

addition, use recommended fuels, coolants  and

lubricants. Use the Operation and  Maintenance

Manual as a guide for required engine maintenance.

Number of Cylinders

Bore

3 In-Line

105 mm (4.134 inch)

127 mm (5.0 inch)

Stroke

Aspiration

Turbocharged

Naturally aspirated

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 engine 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.

Compression Ratio

NA 19.25:1

T 18.25:1

Displacement

3.3 L  (201 in )

3

1 2  3

Firing Order

Rotation (flywheel end)

Valve Lash Setting (Inlet)

Counterclockwise

0.20 mm (0.008 inch)

0.45 mm (0.018 inch)

Valve Lash  Setting

(Exhaust)

Engine Cooling and Lubrication

The cooling system  consists of the following

components:

•  Gear-driven centrifugal water pump

•  Water temperature regulator which regulates the

engine coolant temperature

•  Gear-driven oil pump (gear type)

•  Oil cooler

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16

SEBU8352

Product Information Section

Product Identification Information

Product Identification

Information

i02813999

Engine Identification

Perkins engines are identified by a serial number.

This number is shown on a serial number plate that

is mounted on the left hand side of the engine block.

An example  of an  engine number  is

XK12345U090001P.

XK __________________________________________Type of engine

XK12345____________________________Engine List Number

U ____________________________Built in the United Kingdom

090001 ___________________________Engine Serial Number

P _____________________________________Year of Manufacture

g01431025

Illustration 13

Location of serial number plate

Perkins distributors need these numbers in order to

determine the components that were included with

the engine. This permits accurate identification of

replacement part numbers.

i02875212

Serial Number Plate

g01431032

Illustration 14

The Serial Number Plate is located  on the upper

left side of the engine block above the fuel injection

pump.

Typical serial number plate

(1) Temporary Parts List number

(2) List number

(3) Serial number

(4) Type

The following information is stamped on the Serial

Number Plate: Engine serial number, Model, and

Arrangement number.

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SEBU8352

17

Product Information Section

Product Identification Information

i02164876

Reference Numbers

S/N:  XK11-Up

S/N:  XL11-Up

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  _____________________________________

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  ______________________________________________

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18

SEBU8352

Product Information Section

Product Identification I, nformation

i02869408

Emissions Certification Film

g01350379

Illustration 15

Typical example

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SEBU8352

19

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i02677364

Product Storage

Table 2

i02677363

Required Tools

Part Description

Product Lifting

Part

Number

Tool

A

Qty

1

1772204

1762811

1734115

POWERPART Lay-Up 1

POWERPART Lay-Up 2

POWERPART Lay-Up 3

B

1

C

1

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.

Lubrication System

To help prevent excessive engine  wear, use the

following guidelines:

g00103219

Illustration 16

Complete all of the lubrication recommendations that

are listed in this Operation and Maintenance Manual,

“Maintenance Interval Schedule” (Maintenance

Section).

NOTICE

Never bend the eyebolts and the brackets. Only load

the eyebolts and the brackets under tension. Remem-

ber that the capacity of an eyebolt is less as the angle

between the supporting members and  the object be-

comes less than 90 degrees.

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.

When it  is necessary to  remove a component at  an

angle, only use a link bracket that is properly rated for

the weight.

Use the following guidelines :

•  Completely clean the outside of the engine.

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.

•  Drain the fuel system completely and  refill the

system with preservative fuel. Tooling (A) 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.

Some removals require lifting the fixtures in order to

obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that

are on the engine.

•  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.

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.

•  Renew the canister(s) of the lubricating oil filter.

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20

SEBU8352

Operation Section

Lifting and Storage

•  Fill the oil pan to the Full Mark on the dipstick with

new, clean lubricating oil. Add Tooling (B) to the oil

in order to protect the engine against corrosion. If

Tooling (B) is not available, use a preservative of

the correct specification instead of the lubricating

oil. If a preservative is used, this must be drained

completely at the end of the storage period and

the oil pan must be refilled to the correct level with

normal lubricating oil.

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

cylinder block in order to drain the engine. Ensure

that the drain hole is not restricted.

4.  Open the tap or remove the drain  plug at the

bottom of the radiator in order to drain the radiator.

If the radiator does not have a tap or a drain plug,

disconnect the hose at the bottom of the radiator.

5.  Flush the cooling system with clean water.

Cooling System

6.  Fit the drain plugs and the filler cap. Close the tap

or connect the radiator hose.

To help prevent excessive engine  wear, use the

following guidelines:

7.  Fill the cooling system with an approved antifreeze

mixture because this gives protection  against

corrosion.

NOTICE

Do not drain the coolant while the engine is still hot and

the system is under pressure because dangerous hot

coolant can be discharged.

Note: Certain corrosion inhibitors  could cause

damage to some engine components. Contact the

Service Department of Perkins for advice.

If freezing temperatures are expected, check  the

cooling system for adequate  protection against

freezing. See this Operation  and Maintenance

Manual, “General Coolant Information” (Maintenance

Section).

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

circulate the lubricating oil and the coolant in the

engine.

9.  Disconnect the battery. Put the battery into safe

storage in a fully charged condition. Before the

battery is put into storage, protect the terminals

against corrosion. Tooling (C) can be used on the

terminals.

NOTICE

To prevent frost damage, ensure that all the coolant is

removed from the engine. This is important if the sys-

tem is drained after it has been flushed with water, or if

an antifreeze solution too weak to protect the system

from frost has been used.

10. Clean the crankcase breather if one is installed.

Seal the end of the pipe.

11. Remove the fuel injector nozzles and  spray

Tooling (B) 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 injector

nozzles.

Induction System

•  Remove the air filter  assembly. If necessary,

remove the pipes that are installed between the air

filter assembly and the turbocharger. Spray Tooling

(B) into the turbocharger. The duration of the spray

is printed on the container. Seal the turbocharger

with waterproof tape.

Exhaust System

•  Remove the exhaust pipe. Spray Tooling (B) into

the turbocharger. The duration of  the spray is

printed on the container. Seal the turbocharger

with waterproof tape.

g01356026

Illustration 17

1.  Ensure that the vehicle is on level ground.

2.  Remove the filler cap of the cooling system.

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SEBU8352

21

Operation Section

Lifting and Storage

General Items

•  If the lubricating oil filler is installed on the rocker

cover, remove the filler  cap. If the lubricating

oil filler cap is not installed on the  rocker cover,

remove the rocker cover. Spray Tooling (B) around

the rocker shaft assembly. Replace the filler cap

or the rocker 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 Tooling (C). 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.

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22

SEBU8352

Operation Section

Gauges and Indicators

Gauges and Indicators

1.  Reduce the load and the engine rpm.

2.  Inspect the cooling system for leaks.

i02164190

3.  Determine if the engine must  be shut down

immediately or if the engine can  be cooled by

reducing the load.

Gauges and Indicators

Tachometer  – This gauge indicates engine

speed (rpm). When the throttle control lever

is moved to the full throttle position without

load, the engine is running at high idle. The engine is

running at the full load rpm when the throttle control

lever is at the full throttle  position with maximum

rated load.

Your engine may not have the same gauges or all of

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 the normal operating range by observing

the gauges over a period of time.

NOTICE

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

allowed to exceed high idle rpm.

Noticeable changes in gauge  readings indicate

potential gauge or engine problems. Problems may

also be indicated by gauge readings that  change

even if the  readings are within specifications.

Determine and correct the cause of any significant

change in the readings. Consult your Perkins dealer

or your Perkins distributor for assistance.

Ammeter  – This gauge indicates the

amount of charge or  discharge in the

NOTICE

battery charging circuit. Operation of the

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

If no  oil pressure  is  indicated, STOP  the engine.  If

maximum  coolant temperature  is  exceeded, STOP

the engine. Engine damage can result.

Fuel Level  – This gauge indicates the fuel

level in the fuel tank. The fuel level gauge

operates when the “START/STOP” switch

is in the “ON” position.

Engine Oil Pressure  – The oil pressure

should be greatest after a cold engine is

started. The typical engine oil pressure with

SAE10W30 is 207 to 413 kPa (30 to 60 psi) at rated

rpm.

Service Hour Meter – The gauge indicates

operating time of the engine.

A lower oil pressure is normal at low idle. If the load

is stable and the gauge reading changes, perform

the following procedure:

1.  Remove the load.

2.  Reduce engine speed to low idle.

3.  Check and maintain the oil level.

Jacket Water Coolant Temperature  –

Typical temperature range is 71 to 96°C

(160 to 205°F). The maximum allowable

temperature with the pressurized cooling system at

48 kPa (7 psi) is 110°C (230°F). Higher temperatures

may occur under certain  conditions. The water

temperature reading may vary according to load. The

reading should never exceed the boiling point for the

pressurized system that is being used.

If the engine is operating above the normal  range

and steam becomes apparent, perform the following

procedure:

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SEBU8352

23

Operation Section

Features and Controls

Features and Controls

i02690464

Fuel Shutoff

The fuel shutoff solenoid  is located on the fuel

injection pump.

When the fuel shutoff solenoid  is activated, the

solenoid moves to the “Open” position.

When the fuel shutoff solenoid is deactivated, the

solenoid moves to the “Closed” position.

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24

SEBU8352

Operation Section

Engine Starting

Engine Starting

•  Do not start the engine or move any of the controls

if there is a “DO NOT OPERATE” warning tag or

similar warning tag attached to the start switch or

to the controls.

i02675151

Before Starting Engine

•  Ensure that the areas around the rotating parts are

clear.

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

damaged guards or for missing guards.  Repair

any damaged guards. Replace damaged guards

and/or missing guards.

Before the engine is started, perform the  required

daily maintenance  and any other  periodic

maintenance that is due. Refer  to the Operation

and Maintenance Manual, “Maintenance Interval

Schedule” for more information.

•  Disconnect any battery chargers  that are not

protected against the high  current drain that

is created when the  electric starting motor is

engaged. Check electrical cables and check the

battery for poor connections and for corrosion.

•  For the maximum service life of the engine, make a

thorough inspection within the engine compartment

before the engine is started. Look for the following

items: oil leaks, coolant leaks, loose  bolts, and

excessive dirt and/or grease. Remove any excess

dirt and/or grease buildup. Repair any faults that

were identified during the inspection.

•  Reset all of the shutoffs or alarm components (if

equipped).

•  Check the engine lubrication oil level. Maintain the

oil level between the “MIN” mark and the “MAX”

mark on the engine oil level gauge.

•  Inspect the cooling system hoses for cracks and

for loose clamps.

•  Inspect the alternator and accessory drive belts for

cracks, breaks, and other damage.

•  Check the coolant level. Observe the coolant level

in the header tank (if  equipped). Maintain the

coolant level to the “FULL” mark on  the header

tank.

•  Inspect the wiring for loose connections and for

worn wires or frayed wires.

•  If the engine is not equipped with a header tank

maintain the coolant level within 13 mm (0.5 inch)

of the bottom of the  filler pipe. If the engine is

equipped with a sight glass, maintain the coolant

level in the sight glass.

•  Check the fuel supply. Drain water from the water

separator (if equipped). Open the fuel supply valve

(if equipped).

NOTICE

•  Observe the air  cleaner service indicator (if

equipped). Service the air cleaner when the yellow

diaphragm enters the red zone, or when the red

piston locks in the visible position.

All valves in the fuel return  line must be open before

and during engine operation to help prevent high fuel

pressure. High fuel pressure may cause filter housing

failure or other damage.

•  Ensure that any equipment that is driven by the

engine has been disengaged from the  engine.

Minimize electrical loads or remove any electrical

loads.

If the engine has not been started for several weeks,

fuel may have drained from  the fuel system. Air

may have entered the filter housing. Also, when fuel

filters have been changed, some air pockets will be

trapped in the engine. In these instances, prime the

fuel system. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” for more information

on priming the fuel system.

Engine exhaust contains products of combustion

which may be harmful to your health. Always start

and operate  the engine  in a well  ventilated area

and, if in an enclosed area, vent the exhaust to the

outside.

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SEBU8352

25

Operation Section

Engine Starting

i02198348

When Group 2 diesel fuel is used, the following items

provide a means of minimizing starting  problems

and fuel problems in cold weather: engine  oil pan

heaters, jacket water heaters, fuel heaters, and fuel

line insulation.

Starting the Engine

Use the procedure that follows  for cold weather

starting.

Do not use aerosol types of starting aids such as

ether. Such use could  result in an explosion and

personal injury.

1.  If equipped, move the throttle lever to  the full

throttle position before you start the engine.

2.  If equipped, turn the engine start switch to the

HEAT position. Hold the engine start switch in the

HEAT position for 6 seconds until the glow plug

indicator light illuminates. This will activate the

glow plugs and aid in the starting of the engine.

Refer to the OMM for your type of controls. Use the

following procedure to start the engine.

1.  If equipped, move the throttle lever to  the full

throttle position before you start the engine.

NOTICE

NOTICE

Do not  crank the engine  for more than  30 seconds.

Allow the electric starting motor to cool for two minutes

before cranking the engine again.

Do not  crank the engine  for more than  30 seconds.

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 the engine.

2.  Turn the engine start switch to the START position.

Hold the engine start switch in the START position

and crank the engine.

Note: If the glow  plug indicator light illuminates

rapidly for 2 to 3 seconds, or if the glow plug indicator

light fails to illuminate, a malfunction exists in the cold

start system. Do not use ether or other starting fluids

to start the engine.

3.  When the engine starts, release the engine start

switch.

4.  If equipped, slowly move the throttle lever to the

low idle position and allow the engine to idle. Refer

to the Operation and Maintenance Manual, “After

Starting Engine” topic.

4.  When the engine starts, release the engine start

switch key.

5.  If the engine does not start, release the engine

start switch and allow the electric starting motor to

cool. Then, repeat steps 2 through step 4.

5.  If the engine does not start, release the engine

start switch and allow the starter motor to cool.

Then, repeat steps 2 through step 4.

6.  Turn the engine start switch to the OFF position in

order to stop the engine.

6.  If the engine is equipped with a throttle allow the

engine to idle for three to five minutes, or allow the

engine to idle until the water temperature indicator

begins to rise. The engine should run at low idle

smoothly until speed is gradually increased to high

idle. Allow the white smoke to  disperse before

proceeding with normal operation.

i02198092

Cold Weather Starting

7.  Operate the engine at low load until all systems

reach operating temperature. Check the gauges

during the warm-up period.

Do not use aerosol types of starting aids such as

ether. Such use could  result in an explosion and

personal injury.

8.  Turn the engine start switch to the OFF position in

order to stop the engine.

Startability will be improved at temperatures below

−18 °C (0 °F) from the use of a jacket water heater

or extra battery capacity.

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26

SEBU8352

Operation Section

Engine Starting

i02177935

3.  Connect one negative end of the jump start cable

to the negative cable terminal of  the electrical

source. Connect the other negative end of  the

jump start cable to the  engine block or to the

chassis ground. This procedure helps to prevent

potential sparks from igniting the combustible

gases that are produced by some batteries.

Starting with  Jump Start

Cables

4.  Start the engine.

Improper jump start cable connections can cause

an explosion resulting in personal injury.

5.  Immediately after the stalled engine is started,

disconnect the jump start cables in reverse order.

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.

After jump starting, the alternator may not be able to

fully recharge batteries that are severely discharged.

The batteries must be replaced or charged  to the

correct voltage with a battery charger after the engine

is stopped. Many batteries which are  considered

unusable are still rechargeable. Refer to Operation

and Maintenance Manual, “Battery - Replace” and

Testing and Adjusting Manual, “Battery - Test”.

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.

i01903609

After Starting Engine

NOTICE

Using a battery source  with the same voltage as the

electric starting  motor. Use  ONLY equal  voltage for

jump starting. The use of higher  voltage will damage

the electrical system.

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.

Do not reverse the battery cables. The alternator can

be damaged.  Attach ground  cable last  and remove

first.

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.

When using an external  electrical source to start the

engine, turn  the generator  set control  switch to  the

“OFF” position. Turn all electrical accessories OFF be-

fore attaching the jump start cables.

•  Operate the engine at low idle until  all systems

achieve operating temperatures. Check all gauges

during the warm-up period.

Ensure that the main power switch is in the OFF posi-

tion before attaching the jump start  cables to the en-

gine being started.

Note: Gauge readings should be  observed and

the data should be recorded frequently  while the

engine is operating. Comparing the data over time

will help to determine normal  readings for each

gauge. Comparing data over  time will also help

detect abnormal operating developments. Significant

changes in the readings should be investigated.

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

all the engine’s accessories.

2.  Connect one positive end of the jump start cable

to the positive cable terminal of the discharged

battery. Connect the other positive end of the jump

start cable to the positive cable terminal  of the

electrical source.

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SEBU8352

27

Operation Section

Engine Operation

Engine Operation

i02330149

Fuel Conservation Practices

i02176671

Engine Operation

The efficiency of the  engine can affect the fuel

economy. Perkins design  and technology in

manufacturing provides maximum fuel efficiency in

all applications. Follow the recommended procedures

in order to attain optimum performance for the life

of the engine.

Correct operation and maintenance are key factors

in obtaining the maximum  life and economy of

the engine. If the directions in  the Operation and

Maintenance Manual are followed, costs can  be

minimized and engine service life can be maximized.

•  Avoid spilling fuel.

The engine can be operated at the rated rpm after the

engine reaches operating temperature. The engine

will reach normal operating temperature  sooner

during a low engine speed (rpm) and during a low

power demand. This procedure is more effective than

idling the engine at no load. The engine should reach

operating temperature in a few minutes.

Fuel expands when the fuel is warmed up. The fuel

may overflow from the fuel tank. Inspect fuel lines for

leaks. Repair the fuel lines, as needed.

•  Be aware of the properties of the different fuels.

Use only the recommended fuels.

•  Avoid unnecessary idling.

Gauge readings should be observed and the data

should be recorded frequently  while the engine

is operating. Comparing the  data over time will

help to determine normal readings for each gauge.

Comparing data over time  will also help detect

abnormal operating developments. Significant

changes in the readings should be investigated.

Shut off the engine rather than idle for long periods of

time.

•  Observe the air cleaner service indicator frequently.

Keep the air cleaner elements clean.

•  Maintain the electrical systems.

i01929404

One damaged battery cell will overwork the alternator.

This will consume excess power and excess fuel.

Engine Warm-up

•  Ensure that the drive belts are correctly adjusted.

The drive belts should be in good condition.

1.  Run the engine at low idle for three to five minutes,

or run the engine at low idle until the jacket water

temperature starts to rise.

•  Ensure that all of the connections of the hoses are

tight. The connections should not leak.

•  Ensure that the driven  equipment is in good

working order.

More time  may be necessary  when the

temperature is below −18°C (0°F).

•  Cold engines consume excess fuel. Utilize heat

from the jacket water system  and the exhaust

system, when possible. Keep cooling  system

components clean and keep  cooling system

components in good repair. Never operate  the

engine without water temperature  regulators.

All of these items will  help maintain operating

temperatures.

2.  Check all of the gauges during  the warm-up

period.

3.  Perform a walk-around inspection. Check the

engine for fluid leaks and air leaks.

4.  Increase the rpm to the rated rpm.  Check for

fluid leaks and air leaks.  The engine may be

operated at full rated rpm and at full load  when

the temperature of the water jacket reaches 60°C

(140°F).

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28

SEBU8352

Operation Section

Engine Stopping

Engine Stopping

Stopping the Engine

NOTICE

i02818879

After Stopping Engine

i01929389

Note: Before you check the engine oil, do not operate

the engine for at least 10 minutes in order to allow

the engine oil to return to the oil pan.

•  Check the crankcase oil level. Maintain the oil level

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

the oil level dipstick.

Stopping  the engine  immediately  after it  has  been

working under load can result in overheating and ac-

celerated wear of the engine components.

•  If necessary, perform minor adjustments. Repair

any leaks and tighten any loose bolts.

If the engine  has been operating at  high rpm and/or

high loads, run  at low idle  for at least three  minutes

to reduce  and stabilize  internal  engine temperature

before stopping the engine.

•  Note the required  service interval. Perform

the maintenance that is  in the Operation and

Maintenance Manual, “Maintenance Interval

Schedule”.

Avoiding  hot  engine  shutdowns  will  maximize  tur-

bocharger shaft and bearing life.

•  Fill the fuel  tank in order  to help prevent

accumulation of moisture in the fuel. Do not overfill

the fuel tank.

Prior to stopping an engine that is being operated

at low loads, operate the engine at low  idle for 30

seconds before stopping. If the engine  has been

operating at highway speeds and/or at high loads,

operate the engine at  low idle for at least three

minutes. This procedure will  cause the internal

engine temperature to be reduced and stabilized.

NOTICE

Only use antifreeze/coolant mixtures recommended in

the Refill Capacities and Recommendations topic that

is in this Operation and Maintenance Manual. Failure

to do so can cause engine damage.

Ensure that the  engine stopping procedure is

understood. Stop the engine according to the shutoff

system on the engine or refer to the instructions that

are provided by the OEM.

Pressurized System: Hot coolant  can cause seri-

ous 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 pres-

sure.

•  To stop the engine, turn the ignition key switch to

the OFF position.

i01903586

Emergency Stopping

•  Allow the engine to cool. Check the coolant level.

•  If freezing temperatures are expected, check the

coolant for the correct antifreeze protection. The

cooling system must be protected against freezing

to the lowest expected outside temperature. Add

the correct coolant/water mixture, if necessary.

NOTICE

Emergency shutoff controls are for EMERGENCY use

ONLY. DO  NOT  use emergency  shutoff devices  or

controls for normal stopping procedure.

•  Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in

the instructions from the OEM.

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.

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SEBU8352

29

Operation Section

Cold Weather Operation

Cold Weather Operation

•  Install the correct specification of engine lubricant

before the beginning of cold weather.

•  Check all rubber parts (hoses, fan drive belts, etc)

weekly.

i02717265

Cold Weather Operation

•  Check all electrical wiring and connections for any

fraying or damaged insulation.

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:

•  Keep all batteries fully charged and warm.

•  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.

•  The type of fuel that is used

•  The viscosity of the engine oil

•  The operation of the glow plugs

•  Optional Cold starting aid

•  Ensure that the glow plugs are in working order.

Refer to Testing and Adjusting Manual, “Glow Plug

- Test”.

•  Battery condition

Personal  injury  or property  damage  can  result

from alcohol or starting fluids.

This section will cover the following information:

•  Potential problems that are caused by cold weather

operation

Alcohol or starting fluids are highly flammable and

toxic and if improperly stored could result in injury

or property damage.

•  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).

Do not use aerosol types of starting aids such as

ether. Such use could  result in an explosion and

personal injury.

The operation and maintenance of  an engine in

freezing temperatures is complex . This is because

of the following conditions:

•  Weather conditions

•  Engine applications

•  For jump starting with cables  in cold weather,

refer to the Operation and Maintenance Manual,

“Starting with Jump Start Cables.” for instructions.

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.

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.

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.

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.

•  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

down for a period of time and the engine can still

have the ability to start readily.

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30

SEBU8352

Operation Section

Cold Weather Operation

In cold weather, check  the coolant often for the

correct glycol concentration in  order to ensure

adequate freeze protection.

•  Free operation of the valves is prevented.

•  Valves become stuck.

•  Pushrods may become bent.

Engine Block Heaters

•  Other damage to valve train  components can

result.

Engine block heaters  (if equipped) heat  the

engine jacket water that surrounds the combustion

chambers. This provides the following functions:

For this reason,  when the engine is  started,

the engine must  be operated until the coolant

temperature is 71 °C (160 °F)  minimum. Carbon

deposits on the valve stems will be kept at a minimum

and the free operation of the valves and the valve

components will be maintained.

•  Startability is improved.

•  Warm up time is reduced.

An electric block heater  can be activated once

the engine is stopped. An  effective block heater

is typically a  1250/1500 W unit. Consult your

Perkins dealer or your Perkins distributor for more

information.

In addition, the engine must be thoroughly warmed in

order to keep other engine parts in better condition

and the service life of the engine will  be generally

extended. Lubrication will be improved. There will be

less acid and less sludge in the oil. This will provide

longer service life for the engine bearings, the piston

rings, and other parts. However, limit unnecessary

idle time to ten minutes in order to reduce wear and

unnecessary fuel consumption.

Idling the Engine

When idling after the  engine is started in cold

weather, increase the engine rpm from 1000 to 1200

rpm. This will warm up  the engine more quickly.

Maintaining an elevated low idle speed for extended

periods will be easier with the installation of a hand

throttle. The engine should not be “raced” in order to

speed up the warm up process.

The Water Temperature Regulator and

Insulated Heater Lines

The engine is equipped with a water temperature

regulator. When the engine coolant  is below the

correct operating temperature jacket water circulates

through the engine cylinder  block and into the

engine cylinder head. The coolant then returns to the

cylinder block via an internal passage that bypasses

the valve of the coolant temperature regulator. This

ensures that coolant flows around the engine under

cold operating conditions. The water temperature

regulator begins to open when  the engine jacket

water has reached the correct minimum operating

temperature. As the jacket water coolant temperature

rises above the minimum operating temperature the

water temperature regulator opens further allowing

more coolant through the radiator to dissipate excess

heat.

While the engine is idling, the application of a light

load (parasitic load) will  assist in achieving the

minimum operating temperature. The  minimum

operating temperature is 82 °C (179.6 °F).

Recommendations for Coolant

Warm Up

Warm up an engine that has cooled below normal

operating temperatures due to inactivity. This should

be performed before the engine is returned  to full

operation. During operation in very cold temperature

conditions, damage to engine valve mechanisms can

result from engine operation for short intervals. This

can happen if the engine is started and the engine is

stopped many times without being operated in order

to warm up completely.

The progressive opening of the water temperature

regulator operates the progressive closing of  the

bypass passage between the cylinder block  and

head. This ensures  maximum coolant flow to

the radiator in order  to achieve maximum heat

dissipation.

When the engine is operated below normal operating

temperatures, fuel and oil are not completely burned

in the combustion chamber. This fuel and oil causes

soft carbon deposits to form  on the valve stems.

Generally, the deposits do not cause problems and

the deposits are burned  off during operation at

normal engine operating temperatures.

Note: Perkins discourages the use of  all air flow

restriction devices such  as radiator shutters.

Restriction of the air flow can result in the following:

high exhaust temperatures, power loss, excessive

fan usage, and reduction in fuel economy.

When the engine is started and the engine is stopped

many times without being operated in order to warm

up completely, the carbon deposits become thicker.

This can cause the following problems:

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SEBU8352

31

Operation Section

Cold Weather Operation

A cab heater is beneficial in very cold weather. The

feed from the engine and the return lines from the

cab should be insulated in order to reduce heat loss

to the outside air.

When Group 2 diesel fuels are used the following

components provide a means of minimizing problems

in cold weather:

•  Glow plugs (if equipped)

Insulating the Air  Inlet and Engine

Compartment

•  Engine coolant heaters, which may be an OEM

option

When temperatures below −18 °C (−0  °F) will be

frequently encountered, an air cleaner  inlet that

is located in  the engine compartment may be

specified. An air cleaner th, at is located in the engine

compartment may also minimize the entry of snow

into the air cleaner. Also, heat that is rejected by the

engine helps to warm the intake air.

•  Fuel heaters, which may be an OEM option

•  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 different characteristics to Group 2 fuels.

Additional heat can be retained around the engine by

insulating the engine compartment.

•  A lower cloud point

•  A lower pour point

i02322217

Fuel and the Effect from Cold

Weather

•  A higher energy per unit volume of fuel

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

use of Group 3 fuels is not covered by the Perkins

warranty.

Group 3 fuels include Low Temperature Fuels and

Aviation Kerosene Fuels.

Note: Only use grades of fuel that are recommended

by Perkins. Refer to this Operation and Maintenance

Manual, “Fluid Recommendations”.

Special fuels include Biofuel.

The following fuels can be  used in this series of

engine.

The cloud point is a temperature  that allows wax

crystals to form in the fuel. These crystals can cause

the fuel filters to plug.

•  Group 1

The pour point is the temperature when diesel fuel

will thicken. The diesel fuel becomes more resistant

to flow through fuel lines, fuel filters,and fuel pumps.

•  Group 2

•  Group 3

Be aware of  these facts when  diesel fuel is

purchased. Consider the average  ambient air

temperature for the engine’s application. Engines

that are fueled in one climate may not operate well if

the engines are moved to another climate. Problems

can result due to changes in temperature.

•  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.

Before troubleshooting for low power  or for poor

performance in the winter, check the fuel for waxing.

Low temperature fuels may be available for engine

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

fuels limit the formation of  wax in the fuel at low

temperatures.

Note: Group 2 fuels must have a  maximum wear

scar of 650 micrometers (HFRR to ISO 12156-1).

For more information on cold weather operation, refer

to the Operation and Maintenance Manual, “Cold

Weather Operation and Fuel Related Components in

Cold Weather”.

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.

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32

SEBU8352

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 tanks use supply pipes that allow water

and sediment to settle below  the end of the fuel

supply pipe.

Some fuel tanks use  supply lines that take fuel

directly from the bottom of the tank. If the engine is

equipped with this system, regular maintenance of

the fuel system filter is important.

Drain the water and sediment from any fuel storage

tank at the following intervals: weekly, oil changes,

and refueling of the fuel tank. This will help prevent

water and/or sediment from being pumped from the

fuel storage tank and into the engine fuel tank.

Fuel Filters

It is possible that a  primary fuel filter is installed

between the fuel tank and the engine fuel inlet. After

you change the fuel filter,  always prime the fuel

system in order to remove air bubbles from the fuel

system. Refer to the Operation and Maintenance

Manual in the  Maintenance Section for more

information on priming the fuel system.

The micron rating and the location of a primary fuel

filter is important in cold  weather operation. The

primary fuel filter and the fuel supply line are the most

common components that are affected by cold fuel.

Fuel Heaters

Note: The OEM may equip the application with fuel

heaters. If this is the case, disconnect an electric type

of fuel heater in warm weather in order to prevent

overheating of the fuel. If the type of fuel heater is a

heat exchanger, the OEM should have included a

bypass for warm weather. Ensure that the bypass is

operational during warm weather in order to prevent

overheating of the fuel.

For more information about fuel heaters (if equipped),

refer to the OEM information.

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SEBU8352

33

Maintenance Section

Refill Capacities

Maintenance Section

1103D Engine

Table 4

1103D Naturally  Aspirated Engine without

an oil  cooler

Refill Capacities

Compartment or System

Engine Only

External cooling system capacity

Liters

Quarts

i02814021

4.21

4

Refill Capacities

(OEM recommendation)

(1)

Total Cooling System

(2)

(1)  The external cooling system  includes a radiator or  an

Lubrication System

expansion tank with the following components: heat exchanger,

aftercooler, and piping. Refer to the OEM specifications. Enter

the value for the external system capacity in this row.

(2)  The Total Cooling System includes the capacity for the engine

cooling system plus the  capacity for the external cooling

system. Enter the total in this row.

The refill capacities  for the engine crankcase

reflect the approximate capacity of the crankcase

or sump plus standard oil filters. Auxiliary  oil filter

systems will require additional oil. Refer to the OEM

specifications for the capacity of the auxiliary oil filter.

Refer to the Operation and Maintenance Manual,

“Maintenance Section” for more  information on

Lubricant Specifications.

Table 5

1103D Naturally  Aspirated Engines  and

Turbocharged Engines with an oil cooler

Compartment or System

Engine Only

External cooling system capacity

Liters

Quarts

1103D Engine

4.43

4.02

Table 3

(OEM recommendation)

(1)

1103D Engine

Total Cooling System

(2)

Compartment or System

Liters

Quarts

(1)  The external cooling system  includes a radiator or  an

Standard Oil Sump for the Engine

expansion tank with the following components: heat exchanger,

aftercooler, and piping. Refer to the OEM specifications. Enter

the value for the external system capacity in this row.

(2)  The Total Cooling System includes the capacity for the engine

cooling system plus the  capacity for the external cooling

system. Enter the total in this row.

6.5

7

Crankcase

(1)

(1)  These values are the approximate capacities for the crankcase

oil sump which include the standard factory installed oil filters.

Engines with auxiliary oil filters will require additional oil. Refer

to the OEM specifications for the capacity of the  auxiliary oil

filter.

i02883944

Cooling System

Fluid Recommendations

To maintain the cooling system, the Total  Cooling

System capacity must be known. The approximate

capacity for the engine  cooling system is listed

below. 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/antifreeze that is required for  the Total

Cooling System.

Cooling System Specifications

General Coolant Information

NOTICE

Never add coolant  to an overheated  engine. Engine

damage could result. Allow the engine to cool first.

NOTICE

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

with below freezing temperatures, the cooling system

must be either protected to the lowest outside temper-

ature or drained completely to prevent damage.

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34

SEBU8352

Maintenance Section

Refill Capacities

Table 6

NOTICE

Frequently check the specific gravity of the coolant for

proper freeze protection or for anti-boil protection.

Acceptable Water

Maximum Limit

Property

Chloride (Cl)

Sulfate (SO4)

Total Hardness

Total Solids

Acidity

40 mg/L

100 mg/L

Clean the cooling system for the following reasons:

•  Contamination of the cooling system

•  Overheating of the engine

170 mg/L

340 mg/L

pH of  5.5 to 9.0

•  Foaming of the coolant

For a water analysis, consult one of  the following

sources:

NOTICE

Never operate  an engine without  water temperature

regulators in the  cooling system. Water  temperature

regulators help to maintain  the engine coolant at the

proper operating temperature.  Cooling system prob-

lems can develop  without water temperature regula-

tors.

•  Local water utility company

•  Agricultural agent

•  Independent laboratory

Additives

Many engine failures are  related to the cooling

system. The following problems are related to cooling

system failures: Overheating, leakage of the water

pump, and plugged radiators or heat exchangers.

Additives help to protect  the metal surfaces of

the cooling system. A lack of coolant  additives or

insufficient amounts of additives enable the following

conditions to occur:

These failures can be avoided with correct cooling

system maintenance. Cooling system maintenance is

as important as maintenance of the fuel system and

the lubrication system. Quality of the coolant is as

important as the quality of the fuel and the lubricating

oil.

•  Corrosion

•  Formation of mineral deposits

•  Rust

Coolant is normally composed of three elements:

Water, additives, and glycol.

•  Scale

•  Foaming of the coolant

Water

Many additives are depleted during engine operation.

These additives must be replaced periodically.

Water is used in  the cooling system in order to

transfer heat.

Additives must be added at the correct concentration.

Overconcentration of additives  can cause the

inhibitors to drop out-of-solution. The deposits can

enable the following problems to occur:

Distilled water  or deionized  water is

recommended for use in engine cooling systems.

DO NOT use the following types of water in cooling

systems: Hard water, softened water that has been

conditioned with salt, and sea water.

•  Formation of gel compounds

•  Reduction of heat transfer

If distilled water or deionized water is not available,

use water with the properties that are listed in Table 6.

•  Leakage of the water pump seal

•  Plugging of radiators, coolers, and small passages

Glycol

Glycol in the coolant helps  to provide protection

against the following conditions:

•  Boiling

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SEBU8352

35

Maintenance Section

Refill Capacities

•  Freezing

NOTICE

•  Cavitation of the water pump

Do not use  a commercial coolant/antifreeze that  on-

ly meets the ASTM D3306 specification.  This type of

coolant/antifreeze is made for  light automotive appli-

cations.

For optimum performance, Perkins recommends a

1:1 mixture of a water/glycol solution.

Note: Use a mixture that  will provide protection

against the lowest ambient temperature.

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.

This ratio may be increased to 1:2 water to glycol if

extra freezing protection is required.

Note: 100 percent  pure glycol will freeze at  a

temperature of −23 °C (−9 °F).

Most conventional antifreezes use ethylene glycol.

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

with water, ethylene and propylene glycol provide

similar protection against freezing and boiling. See

Tables 7 and 8.

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.

Table 7

In stationary engine 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.

Ethylene Glycol

Freeze

Protection

Boil

Protection

Concentration

50 Percent

60 Percent

−36 °C (−33 °F)   106 °C (223 °F)

−51 °C (−60 °F)   111 °C (232 °F)

NOTICE

Engines that are operating in an ambient temperature

above 43 °C (109.4 °F) must use SCA and  water.

Engines that operate in an  ambient temperature

above 43 °C (109.4 °F) and below 0 °C (32 °F) due

to seasonal variations consult your Perkins dealer

or your Perkins distributor for the  correct level of

protection.

Do not use propylene glycol in concentrations that ex-

ceed 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 8

Table 9

Propylene Glycol

Coolant Service  Life

Freeze

Protection

Anti-Boil

Protection

Concentration

Coolant Type

Service Life

6,000 Service Hours  or

Three Years

50 Percent

−29 °C (−20 °F)     106 °C (223 °F)

Perkins ELC

Commercial Heavy-Duty

Antifreeze that meets

“ASTM D4985”

To check the concentration of glycol in the coolant,

measure the specific gravity of the coolant.

3000 Service Hours  or

Two Years

Coolant Recommendations

Perkins POWERPART

SCA

3000 Service Hours  or

Two Years

The following two coolants are used in Perkins diesel

engines:

Commercial SCA and

Water

3000 Service Hours  or

Two Years

Preferred  – Perkins Extended Life Coolant (ELC)

Extended Life Coolant (ELC)

Acceptable  – A commercial heavy-duty antifreeze

that meets “ASTM D4985” specifications

Perkins provides Extended Life Coolant (ELC) for

use in the following applications:

•  Heavy-duty spark ignited gas engines

•  Heavy-duty diesel engines

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36

SEBU8352

Maintenance Section

Refill Capacities

•  Automotive applications

ELC Cooling System Cleaning

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.

Note: If the cooling system is already using  ELC,

cleaning agents are not  required to be used at

the specified coolant change  interval. Cleaning

agents are only required if  the system has been

contaminated by the addition of some other type of

coolant or by cooling system damage.

Clean water is the only cleaning agent that is required

when ELC is drained from the cooling system.

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.

After the cooling system is  drained and after the

cooling system is refilled, operate the engine while

the cooling system filler cap is removed.  Operate

the engine until the coolant level reaches the normal

operating temperature and until the coolant level

stabilizes. As needed, add the coolant  mixture in

order to fill the system to the specified level.

ELC Concentrate is also available. ELC Concentrate

can be used to lower the freezing point  to −51 °C

(−60 °F) for arctic conditions.

Changing to Perkins ELC

Containers of several sizes are available. Consult

your Perkins dealer or your Perkins distributor for the

part numbers.

To change from heavy-duty antifreeze to the Perkins

ELC, perform the following steps:

NOTICE

ELC Cooling System Maintenance

Care  must  be  taken  to  ensure  that  all  fluids  are

contained  during  performance of  inspection,  main-

tenance,  testing,  adjusting   and  the  repair  of   the

product. Be prepared to collect the fluid  with suitable

containers before  opening any  compartment or  dis-

assembling any component containing fluids.

Correct additions to the Extended Life

Coolant

NOTICE

Use only Perkins  products for pre-mixed  or concen-

trated coolants.

Dispose of all fluids according to local regulations and

mandates.

Mixing Extended Life Coolant with other products re-

duces the Extended Life Coolant service life. Failure to

follow the recommendations can reduce cooling  sys-

tem components life unless appropriate corrective ac-

tion is performed.

1.  Drain the coolant into a suitable container.

2.  Dispose of the coolant  according to local

regulations.

3.  Flush the system with clean water in  order to

remove any debris.

In order to maintain the correct  balance between

the antifreeze and the additives, you must maintain

the recommended concentration of Extended Life

Coolant (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.

4.  Use Perkins cleaner to clean the system. Follow

the instruction on the label.

5.  Drain the cleaner into a suitable container. Flush

the cooling system with clean water.

NOTICE

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

system that is filled with Extended Life Coolant (ELC).

6.  Fill the cooling system with clean  water and

operate the engine until the engine is warmed to

49° to 66°C (120° to 150°F).

Do not  use  standard supplemental  coolant additive

(SCA).

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

or SCA filters.

This document has been printed from SPI². Not for Resale

 

SEBU8352

37

Maintenance Section

Refill Capacities

Commercial Heavy-Duty Antifreeze and

SCA

NOTICE

Incorrect or incomplete flushing of the cooling system

can result in damage to copper and other metal com-

ponents.

NOTICE

Commercial   Heavy-Duty  Coolant   which   contains

Amine as part of the corrision protection system must

not be used.

To avoid damage to the cooling system, make sure to

completely flush the cooling system with  clear water.

Continue to flush the system until  all the signs of the

cleaning agent are gone.

NOTICE

Never operate  an engine without  water temperature

regulators in the  cooling system. Water  temperature

regulators help to maintain  the engine coolant at the

correct operating temperature. Cooling  system prob-

lems can develop  without water temperature regula-

tors.

7.  Drain the cooling system into a suitable container

and flush the cooling system with clean water.

Note: The cooling system cleaner must be thoroughly

flushed from the cooling system. Cooling  system

cleaner that is left in the system will contaminate the

coolant. The cleaner may also corrode the cooling

system.

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.

8.  Repeat Steps 6 and  7 until the system  is

completely clean.

Perkins engine cooling systems should be tested

at 500 hour  intervals for the concentration of

Supplemental Coolant Additive (SCA).

9.  Fill the cooling system with the Perkins Premixed

ELC.

Additions of SCA are based on the results of the test.

An SCA that is liquid may be needed  at 500 hour

intervals.

ELC Cooling System Contamination

NOTICE

Mixing ELC with other products reduces the effective-

ness of  the ELC and  shortens the  ELC service life.

Use only  Perkins Products  for premixed or  concen-

trate coolants.  Failure to follow  these recommenda-

tions can result in  shortened cooling system compo-

nent life.

Refer to Table 10 for part numbers and for quantities

of SCA.

Table 10

Perkins Liquid  SCA

Part Number

Quantity

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:

21825735

10

Adding the SCA to Heavy-Duty Coolant

at the Initial Fill

•  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.

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.

•  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.

Use the equation that is in Table 11 to determine the

amount of Perkins SCA that is required when  the

cooling system is initially filled.

Table 11

•  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.

Equation For Adding The SCA To The Heavy-Duty

Coolant At  The Initial Fill

V ×  0.045 =  X

V is the total volume of the cooling system.

X is the amount of SCA that is required.

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38

SEBU8352

Maintenance Section

Refill Capacities

Table 12 is an example for using the equation that

is in Table 11.

Cleaning the System  of Heavy-Duty

Antifreeze

Table 12

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.

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant At The Initial  Fill

Total Volume

of the Cooling

System (V)

Multiplication

Factor

Amount of SCA

that is Required

(X)

•  Clean the cooling system after used  coolant is

drained or before the cooling system is filled with

new coolant.

15 L (4 US gal)

× 0.045

0.7 L (24 oz)

Adding The SCA to  The Heavy-Duty

Coolant For Maintenance

•  Clean the cooling system whenever the coolant is

contaminated or whenever the coolant is foaming.

Heavy-duty antifreeze of all types REQUIRE periodic

additions of an SCA.

i02883885

Fluid Recommendations

Test the antifreeze periodically for the concentration

of SCA. For the  interval, refer to the Operation

and Maintenance Manual, “Maintenance Interval

Schedule” (Maintenance Section).  Test the

concentration of SCA.

General Lubricant Information

Additions of SCA are based on  the results of the

test. The size of the cooling system determines the

amount of SCA that is needed.

Because of government regulations regarding the

certification of exhaust emissions from the engine,

the lubricant recommendations must be followed.

Use the equation that is in Table 13 to determine the

amount of Perkins SCA that is required, if necessary:

Engine Manufacturers Association (EMA)

Oils

Table 13

The “Engine  Manufacturers Association

Recommended Guideline on Diesel Engine Oil” is

recognized by Perkins. For detailed  information

about this guideline, see the latest edition of EMA

publication, “EMA DHD -1”.

Equation For Adding The SCA To The Heavy-Duty

Coolant For  Maintenance

V ×  0.014 =  X

V is the total volume of the cooling system.

X is the amount of SCA that is required.

API Oils

The Engine Oil Licensing and Certification System by

the American Petroleum Institute (API) is recognized

by Perkins. For detailed  information about this

system, see the latest edition of the “API publication

No. 1509”. Engine oils that bear the API symbol are

authorized by API.

Table 14 is an example for using the equation that

is in Table 13.

Table 14

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant For Maintenance

Total Volume

of the Cooling

System (V)

Multiplication

Factor

Amount of SCA

that is Required

(X)

15 L (4 US gal)

× 0.014

0.2 L (7 oz)

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SEBU8352

39

Maintenance Section

Refill Capacities

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.

g00546535

Illustration 18

Typical API symbol

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.

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

not been API authorized  classifications since 1

January 1996. Table 15 summarizes the status of

the classifications.

Table 15

API Classifications

Current

CH-4, ,  CI-4

-

Obsolete

CE, CC,  CD

CD-2  (1)

All DHD-1 oils must complete a  full test program

with the base stock and with the viscosity grade of

the finished commercial oil. The use of “API  Base

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.

(1)  The oil CD-2 is for a two-cycle diesel engine. Perkins does not

sell engines that utilize CD-2 oil.

Terminology

Certain abbreviations follow the nomenclature of

“SAE J754”. Some classifications follow “SAE J183”

abbreviations, and some classifications follow the

“EMA Recommended Guideline on Diesel Engine

Oil”. In addition to Perkins definitions, there are other

definitions that will be of assistance in  purchasing

lubricants. Recommended oil viscosities can be found

in this publication, “Fluid Recommendations/Engine

Oil” topic (Maintenance Section).

DHD-1 oils are recommended for use in extended oil

change interval programs that optimize the life of the

oil. These oil change interval programs are based

on oil analysis. DHD-1 oils are recommended  for

conditions that demand a premium oil. Your Perkins

dealer or your Perkins distributor has the  specific

guidelines for optimizing oil change intervals.

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

meet the requirements of the new high performance

diesel engines. Also,  the oil was designed to

meet the requirements of the low emissions diesel

engines. API CH-4 oils are also acceptable for use

in older diesel engines and in diesel  engines that

use high sulfur diesel fuel. API CH-4  oils may be

used in Perkins engines that use API CG-4 and API

CF-4 oils. API CH-4 oils will generally exceed the

performance of API CG-4 oils in the following criteria:

deposits on pistons, control of oil consumption, wear

of piston rings, valve train wear, viscosity control,

and corrosion.

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:

•  API CH-4 CI-4

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SEBU8352

Maintenance Section

Refill Capacities

Three new engine tests were developed for the API

CH-4 oil. The first test specifically evaluates deposits

on pistons for engines with the two-piece steel piston.

This test (piston deposit) also measures the control

of oil consumption. A  second test is conducted

with moderate oil soot. The second test measures

the following criteria: wear of piston rings, wear of

cylinder liners, and resistance to corrosion. A third

new test measures the following characteristics with

high levels of soot in the oil: wear of the valve train,

resistance of the oil in  plugging the oil filter, and

control of sludge.

In addition to the new  tests, API CH-4 oils have

tougher limits for viscosity control in applications that

generate high soot. The oils  also have improved

oxidation resistance. API CH-4 oils must pass an

additional test (piston deposit) for engines that use

aluminum pistons (single piece). Oil performance is

also established for engines that operate in areas

with high sulfur diesel fuel.

g00799818

Illustration 19

(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:

All of these improvements  allow the API CH-4

oil to achieve optimum oil  change intervals. API

CH-4 oils are recommended for use in extended oil

change intervals. API CH-4 oils are recommended

for conditions that demand  a premium oil. Your

Perkins dealer or your Perkins distributor has specific

guidelines for optimizing oil change intervals.

•

•

Choose an oil with the highest TBN that meets one

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

Reduce the oil change  interval. Base the oil

change interval on the oil analysis. Ensure that the

oil analysis includes the condition of the oil and a

wear metal analysis.

Some commercial  oils that meet  the API

classifications may require reduced  oil change

intervals. To determine the oil change interval, closely

monitor the condition of the oil and perform a wear

metal analysis.

Excessive piston deposits can be produced by an oil

with a high TBN. These deposits can lead to a loss

of control of the oil consumption and to the polishing

of the cylinder bore.

NOTICE

Failure to follow these oil recommendations can cause

shortened engine service  life due to deposits  and/or

excessive wear.

NOTICE

Operating Direct Injection (DI) diesel engines with fuel

sulphur levels over 0.5 percent will require shortened

oil change intervals in order to help maintain adequate

wear protection.

Total Base Number (TBN) and Fuel Sulfur

Levels for Direct Injection (DI)  Diesel

Engines

Table 16

Percentage of Sulfur in

the fuel

Oil change interval

The Total Base Number (TBN) for an oil depends on

the fuel sulfur level. For direct injection engines that

use distillate fuel, the minimum TBN of the new oil

must be 10 times the fuel sulfur level.  The TBN is

defined by “ASTM D2896”. The minimum TBN of the

oil is 5 regardless of fuel sulfur level. Illustration 19

demonstrates the TBN.

Lower than 0.5

0.5 to 1.0

Normal

0.75 of normal

0.50 of normal

Greater than 1.0

Lubricant Viscosity Recommendations

for Direct Injection (DI) Diesel Engines

The correct SAE viscosity grade of oil is determined

by the minimum  ambient temperature during

cold engine start-up, and the  maximum ambient

temperature during engine operation.

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SEBU8352

41

Maintenance Section

Refill Capacities

Refer to Table 17 (minimum temperature) in order

to determine the required oil viscosity for starting a

cold engine.

Re-refined Base Stock Oils

Re-refined base stock  oils are acceptable for

use in Perkins  engines if these oils  meet the

performance requirements that are specified  by

Perkins. Re-refined base stock oils  can be used

exclusively in finished oil or in a combination  with

new base stock oils. The US military specifications

and the specifications of other  heavy equipment

manufacturers also allow the use of re-refined base

stock oils that meet the same criteria.

Refer to Table 17 (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 17

The process that is used to make re-refined  base

stock oil should adequately remove all wear metals

that are in the used  oil and all the additives that

are in the used  oil. The process that is used to

make re-refined base stock oil generally involves the

process of vacuum distillation and hydrotreating the

used oil. Filtering is adequate for the production of

high quality, re-refined base stock oil.

Engine Oil  Viscosity

EMA LRG-1

API CH-4

Viscosity Grade

Ambient Temperature

Minimum

Maximum

SAE 0W20

SAE 0W30

SAE 0W40

SAE 5W30

SAE 5W40

SAE 10W30

SAE 15W40

−40 °C (−40 °F)

−40 °C (−40 °F)

−40 °C (−40 °F)

−30 °C (−22 °F)

−30 °C (−22 °F)

−20 °C (−4 °F)

−10 °C (14 °F)

10 °C (50 °F)

30 °C (86 °F)

40 °C (104 °F)

30 °C (86 °F)

40 °C (104 °F)

40 °C (104 °F)

50 °C (122 °F)

Lubricants for Cold Weather

When an engine is started and an engine is operated

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

multigrade oils that are capable  of flowing in low

temperatures.

These oils have lubricant viscosity grades of SAE

0W or SAE 5W.

Synthetic Base Stock Oils

When an engine is started and operated in ambient

temperatures below −30 °C (−22 °F), use a synthetic

base stock multigrade oil with an 0W viscosity grade

or with a 5W viscosity grade. Use an oil with a pour

point that is lower than −50 °C (−58 °F).

Synthetic base oils  are acceptable for use in

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:

The number of acceptable lubricants is  limited in

cold weather conditions. Perkins recommends the

following lubricants for use in cold weather conditions:

•  Synthetic base oils have improved  flow at low

temperatures especially in arctic conditions.

First Choice  – Use oil  with an EMA DHD-1

Recommended Guideline. Use a CH-4 oil that has

an API license. The oil should be either SAE 0W20,

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

lubricant viscosity grade.

•  Synthetic base oils have  improved oxidation

stability especially at high operating temperatures.

Some synthetic base  oils have performance

characteristics that enhance the service life of the

oil. Perkins does not  recommend the automatic

extending of the oil change intervals for any type of

oil.

Second Choice  – Use an oil that  has a CH-4

additive package. Although the oil  has not been

tested for the requirements of the API license, the oil

must be either SAE 0W20, SAE 0W30, SAE 0W40,

SAE 5W30, or SAE 5W40.

NOTICE

Shortened engine  service life  could result if  second

choice oils are used.

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42

SEBU8352

Maintenance Section

Refill Capacities

Aftermarket Oil Additives

•  Tests are  conducted in order  to detect

contamination of the oil by water, glycol or fuel.

Perkins does not recommend the use of aftermarket

additives in oil. It is not necessary to use aftermarket

additives in order to achieve the engine’s maximum

service life or rated performance. Fully formulated,

finished oils consist of base oils and of commercial

additive packages. These additive packages are

blended into the base oils at precise p, ercentages in

order to help provide finished oils with performance

characteristics that meet industry standards.

•  The Oil Condition Analysis determines the loss of

the oil’s lubricating properties. An infrared analysis

is used to compare the properties of new oil to the

properties of the used oil sample. This analysis

allows technicians to determine the amount  of

deterioration of the oil during use. This analysis

also allows technicians to verify the performance

of the oil according to the specification during the

entire oil change interval.

There are no industry standard tests that evaluate

the performance or the compatibility of aftermarket

additives in finished oil. Aftermarket additives may

not be compatible with the  finished oil’s additive

package, which could lower the performance of the

finished oil. The aftermarket additive could  fail to

mix with the finished oil. This could produce sludge

in the crankcase. Perkins discourages the  use of

aftermarket additives in finished oils.

i02883936

Fluid Recommendations   

Fuel Specifications

To achieve the best performance  from a Perkins

engine, conform to the following guidelines:

Fuel Recommendations

To get the correct power  and performance from

the engine, use a fuel  of the correct quality. The

recommended fuel specification for Perkins engines

is shown below:

•  Select the correct oil, or a commercial oil that meets

the “EMA Recommended Guideline on  Diesel

Engine Oil” or the recommended API classification.

•  See the appropriate “Lubricant Viscosities” table in

order to find the correct oil viscosity grade for your

engine.

•  Cetane number___________________________45 minimum

•  Viscosity___________2,0 to 4.5 cSt at 40 °C (104 °F)

•  Density________________________0.835 to 0.855 Kg/liter

•  Sulfur_______________________0.2% of mass, maximum

•  Distillation___________________85% at 350 °C (662 °F)

•  At the specified interval, service the engine. Use

new oil and install a new oil filter.

•  Perform maintenance at the  intervals that are

specified in the  Operation and Maintenance

Manual, “Maintenance Interval Schedule”.

•  Lubricity______________________________460 micrometers

maximum wear scar on “ISO 12156 - 1”

Oil analysis

Cetane number

Some engines may be equipped with an oil sampling

valve. If oil analysis is required the oil sampling valve

is used to obtain samples of the engine oil. The oil

analysis will complement the preventive maintenance

program.

This indicates the properties of ignition of the fuel.

Fuel with a low cetane  number can be the root

cause of problems during cold start. This will affect

combustion.

The oil analysis is a diagnostic tool that is used to

determine oil performance and component wear

rates. Contamination can be identified and measured

through the use of the oil analysis. The oil analysis

includes the following tests:

Viscosity

This is the  resistance to flow of a  fluid. If this

resistance is outside the limits, the engine and the

engine starting performance in particular can  be

affected.

•  The Wear Rate Analysis monitors the wear of the

engine’s metals. The amount of wear metal and

type of wear metal that is in the oil is analyzed. The

increase in the rate of engine wear metal  in the

oil is as important as the quantity of engine wear

metal in the oil.

Sulfur

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SEBU8352

43

Maintenance Section

Refill Capacities

High sulfur content of the fuel is not normally found

in Europe, North America or Australasia. This can

cause engine wear. 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.

“ASTM D975 - 91 Class 1D”

“JP7, Mil T38219”

“NATO F63”

NOTICE

These fuels  should have  a wear  scar  value of  650

Distillation

micrometers maximum *HFRR to ISO 12156 - 1.*

This is an  indication of the mixture of different

hydrocarbons in the fuel. A high ratio of light weight

hydrocarbons can affect the  characteristics of

combustion.

Group 3 (aviation kerosene fuels): Specification

These fuels need additives to achieve lubricity of 650

micrometers wear scar and the reliability of the fuel

pump and fuel injectors will be reduced.  The fuel

injection pump is not covered by a warranty, even

when the additives are included.

Lubricity

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

Diesel engines have the ability to burn a wide variety

of fuels. These fuels are divided into four  general

groups:

“JP5 MIL T5624 (Avcat FSII, NATO F44”

“JP8 T83133 (Avtur FSII, NATO F34”

“Jet A”

•  Group 1 (preferred fuels)

•  Group 2 (permissible fuels)

•  Group 3 (aviation kerosene fuels)

•  Other fuels

“Jet A1, NATO F35, XF63”

Low temperature fuels

Special fuels for use in cold weather may be available

for engine operation at temperatures below  0 °C

(32 °F). These fuels limit the formation of wax in the

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

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

Group 1 (preferred fuels): Specification

“DERV to EN590”

Note: Only use Arctic fuels when the temperature is

below 0 °C (32 °F). Do not use Arctic fuels when the

ambient temperature is above 0 °C (32 °F). To ensure

that the time period between cranking the engine and

first fire is kept to a minimum, only  use fuel of the

correct viscosity and at the correct temperature.

Note: These fuels that lack lubricity may cause the

following problems:

•  Low engine power

•  Difficult starting in  hot conditions or in  cold

conditions

Gas oil to “BS2869 Class A2”

•  White smoke

“ASTM D975 - 91 Class 2D” This can only be used if

the fuel has the correct specification of lubricity.

•  Deterioration of emissions and misfire at certain

operating conditions

“JIS K2204 (1992) Grades 1,2,3 and Special Grade

3” This can only be used if the fuel has the correct

specification of lubricity.

Biofuel: Specification

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

fuel is permitted.

Note: If low sulfur or low sulfur aromatic fuels  are

used, then fuel additives can be used to  increase

lubricity.

NOTICE

Water emulsion fuels: These fuels are not permitted

Group 2 (permissible fuels): Specification

These fuel specifications are considered acceptable

for issues of warranty. However,these  fuels may

reduce the life of the engine, the engine’s maximum

power and the engine’s fuel efficiency.

Refer to the following  fuel specifications for

North America.

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SEBU8352

Maintenance Section

Refill Capacities

The preferred fuels provide maximum engine service

life and performance. The preferred fuels are distillate

fuels. These fuels are commonly called diesel fuel

or gas oil.

(Table 18, contd)

Copper Strip

Corrosion

No. 3 maximum

“D130”

“D86”

10% at 282  °C

(540 °F)

maximum

The permissible fuels are crude oils or blended fuels.

Use of these fuels can result in higher maintenance

costs and in reduced engine service life.

Distillation

90% at 360  °C

(680 °F)

Diesel fuels that meet the specifications  in Table

18 will help to provide maximum engine service life

and performance. In North America, diesel fuel that

is identified as No. 2-D in “ASTM D975” generally

meets the specifications. Table 18 is for diesel fuels

that are distilled from crude oil.  Diesel fuels from

other sources could exhibit detrimental properties

that are not defined or controlled by this specification.

maximum

Flash Point

API Gravity

legal limit

“D93”

30 minimum

45 maximum

“D287”

6 °C  (10 °F)

minimum

below ambient

temperature

Pour Point

“D97”

Table 18

Perkins Specifications for Distillate Diesel Fuel

0.2% maximum

“D3605”

or

“D1552”

Sulfur

(1)

Specifications

Requirements

ASTM Test

Aromatics

35% maximum

“D1319”

2.0 cSt minimum

and 4.5  cSt

maximum at

Kinematic

Viscosity  (2)

0.02% maximum

(weight)

“D445”

Ash

“D482”

“D524”

40 °C (104 °F)

Carbon Residue

on 10% Bottoms

0.35% maximum

(weight)

Water  and

Sediment

0.1% maximum

“D1796”

“D1744”

“D473”

40 minimum (DI

engines)

Cetane Number

“D613”

Water

0.1% maximum

0.05% maximum

(weight)

Sediment

The  cloud

point must not

exceed  the

lowest expected

ambient

Gum and Resins    10  mg per 100

(3)

Cloud Point

-

“D381”

mL maximum

0.38  mm

temperature.

(0.015 inch)

maximum at

25 °C (77 °F)

Lubricity

(4)

“D6079”

(continued)

(1)  Perkins fuel systems and engine components can operate

on high sulfur  fuels. Fuel sulfur  levels affect exhaust

emissions. High sulfur  fuels also increase the potential

for corrosion of  internal components. Fuel sulfur levels

above 0.5 percent may significantly  shorten the oil change

interval. For additional information, see this publication, “Fluid

Recommendations/Engine Oil” topic (Maintenance Section).

(2)  The values of the fuel viscosity are  the values as the fuel

is delivered to the fuel  injection pumps. If a fuel with a low

viscosity is used, cooling of the fuel may be required to maintain

a 1.4 cSt viscosity at the fuel injection pump. Fuels with a high

viscosity might require fuel heaters in order to bring down the

viscosity to a 20 cSt viscosity.

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

(4)  The lubricity of a fuel is a  concern with low sulfur fuel. To

determine the lubricity of the fuel, use either the “ASTM D6078

Scuffing Load Wear Test (SBOCLE)” or the “ASTM D6079 High

Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a

fuel does not meet the minimum requirements,  consult your

fuel supplier. Do not treat the fuel without consulting the  fuel

supplier. Some additives are not compatible. These additives

can cause problems in the fuel system.

This document has been printed from SPI². Not for Resale

 

SEBU8352

45

Maintenance Section

Refill Capacities

NOTICE

Operating with fuels that do not meet the Perkins rec-

ommendations can cause the following effects: Start-

ing difficulty, poor combustion, deposits in the fuel in-

jectors, reduced  service life  of the  fuel system,  de-

posits in the  combustion chamber, and reduced ser-

vice life of the engine.

NOTICE

Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel

must NOT be used in Perkins diesel engines. Severe

component wear and component failures will result if

HFO type fuels are used in engines that are configured

to use distillate fuel.

In extreme cold ambient conditions, you may use the

distillate fuels that are specified in Table 19. However,

the fuel that is selected must meet the requirements

that are specified in  Table 18. These fuels are

intended to be used in operating temperatures that

are down to −54 °C (−65 °F).

Table 19

Distillate Fuels

(1)

Specification

“MIL-T-5624R”

“ASTM D1655”

“MIL-T-83133D”

Grade

JP-5

Jet-A-1

JP-8

(1)  The fuels that are listed  in this Table may not  meet the

requirements that are specified in the “Perkins Specifications

for Distillate Diesel Fuel” Table. Consult the supplier  for the

recommended additives in order to maintain the correct fuel

lubricity.

These fuels are lighter than the No. 2 grades of fuel.

The cetane number of the fuels in Table 19 must be

at least 40. If the viscosity is below 1.4 cSt at 38 °C

(100 °F), use the fuel only in  temperatures below

0 °C (32 °F). Do not use any fuels with a viscosity

of less than 1.2 cSt at 38 °C (100 °F). Fuel cooling

may be required in order to maintain the minimum

viscosity of 1.4 cSt at the fuel injection pump.

There are many other diesel fuel specifications that

are published by governments and by technological

societies. Usually, those  specifications do not

review all the requirements  that are addressed

in this specification. To  ensure optimum engine

performance, a complete fuel analysis should be

obtained before engine operation. The fuel analysis

should include all of the properties that are listed in

Table 18.

This document has been printed from SPI². Not for Resale

 

46

SEBU8352

Maintenance Section

Maintenance Interval Schedule

i02818827

Every 4000 Service Hours

Maintenance Interval Schedule

Aftercooler Core - Clean/Test ...............................  47

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 53

When Required

Battery - Replace .................................................. 49

Battery or Battery Cable - Disconnect ..................  50

Engine - Clean ...................................................... 55

Engine Air Cleaner  Element (Dual Element) -

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 52

Clean/Replace ....................................................  55

Engine Air Cleaner Element  (Single Element) -

Inspect/Replace ..................................................  57

Engine Oil Sample - Obtain ..................................  59

Fuel Injector - Test/Change ................................... 62

Fuel System - Prime .............................................  63

Severe Service Application - Check .....................  68

Daily

Alternator and Fan Belts - Inspect/Adjust/Replace

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

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

Engine Air Cleaner Service Indicator - Inspect ..... 57

Engine Oil Level - Check ......................................  58

Fuel System Primary  Filter/Water Separator -

Drain ...................................................................  64

Walk-Around Inspection ........................................ 70

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 49

Engine Air Cleaner  Element (Dual Element) -

Clean/Replace ....................................................  55

Engine Air Cleaner Element  (Single Element) -

Inspect/Replace ..................................................  57

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

Fuel System Primary  Filter (Water Separator)

Element - Replace ..............................................  65

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

Hoses and Clamps - Inspect/Replace ..................  66

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

Every 1000 Service Hours

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

Every 2000 Service Hours

Aftercooler Core - Inspect ..................................... 47

Alternator - Inspect ...............................................  48

Engine Mounts - Inspect ....................................... 58

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

Turbocharger - Inspect .......................................... 69

Water Pump - Inspect ...........................................  71

Every 3000 Service Hours or 2 Years

Cooling System Coolant (Commercial Heavy-Duty) -

Change ...............................................................  50

This document has been printed from SPI². Not for Resale

 

SEBU8352

47

Maintenance Section

Aftercooler Core - Clean/Test

i02690449

Aftercooler Core - Clean/Test

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-

tective face shield and protective clothing.

1.  Remove the core. Refer to the OEM information

for the correct procedure.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

2.  Turn the aftercooler core upside-down in order to

remove debris.

8.  Dry the core with compressed air. Direct the air in

the reverse direction of the normal flow.

Personal injury can result from air pressure.

9.  Inspect the core in order to ensure cleanliness.

Pressure test the core. If necessary, repair the

core.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-

tective face shield and protective clothing.

10. Install the core. Refer to the OEM information for

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

the correct procedure.

11. After cleaning, start the engine and accelerate

the engine to high idle rpm. This will help in the

removal of debris and drying of the core. Stop the

engine. Use a light bulb behind the core in order

to inspect the core for cleanliness. Repeat  the

cleaning, if necessary.

3.  Pressurized air is the preferred  method for

removing loose debris. Direct  the air in the

opposite direction of the fan’s air flow. Hold the

nozzle approximately 6 mm (.25 inch) away from

the fins. Slowly move the air nozzle in a direction

that is parallel with the tubes. This  will remove

debris that is between the tubes.

i02690450

Aftercooler Core - Inspect

4.  Pressurized water may also be used for cleaning.

The maximum water  pressure for cleaning

purposes must be less than 275 kPa (40 psi). Use

pressurized water in order to soften mud. Clean

the core from both sides.

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

NOTICE

Inspect the aftercooler for these items: damaged fins,

corrosion, dirt, grease, insects, leaves, oil, and other

debris. Clean the aftercooler, if necessary.

Do not use a high concentration of caustic cleaner to

clean the core. A high concentration of caustic cleaner

can attack the internal  metals of the core and  cause

leakage. Only use the recommended concentration of

cleaner.

For air-to-air aftercoolers, use the same methods that

are used for cleaning radiators.

5.  Back flush the core with a suitable cleaner.

6.  Steam clean the core in order to  remove any

residue. Flush the fins of the  aftercooler core.

Remove any other trapped debris.

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-

tective face shield and protective clothing.

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

core thoroughly with clean water.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

This document has been printed from SPI². Not for Resale

 

48

SEBU8352

Maintenance Section

Alternator - Inspect

After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal

of debris and drying of the core. Stop  the engine.

Use a light bulb behind the core in order to inspect

the core for cleanliness.  Repeat the cleaning, if

necessary.

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.

Inspect the fins for damage. Bent fins may be opened

with a “comb”.

If the  belts are too loose,  vibration causes

unnecessary wear on the belts and pulleys. Loose

belts may slip enough to cause overheating.

Note: If parts of the aftercooler system are repaired

or replaced, a leak test is highly recommended.

To accurately check the belt tension, a suitable gauge

should be used.

Inspect these items for  good condition: Welds,

mounting brackets, air lines, connections, clamps,

and seals. Make repairs, if necessary.

i02322311

Alternator - Inspect

Perkins recommends a scheduled inspection  of

the alternator. Inspect  the alternator for loose

connections and correct battery charging. Check the

ammeter (if equipped) during engine operation in

order to ensure correct battery performance and/or

correct performance of the electrical system. Make

repairs, as required.

g01003936

Illustration 20

Typical example

(1) Dial Gauge

Check the alternator and the  battery charger for

correct operation. If  the batteries are correctly

charged, the ammeter reading should be very near

zero. All batteries should  be kept charged. The

batteries should be kept warm because temperature

affects the cranking power. If the battery is too cold,

the battery will not  crank the engine. When the

engine is not run for long periods  of time or if the

engine is run for short periods, the batteries may not

fully charge. A battery with a low charge will freeze

more easily than a battery with a full charge.

Fit the gauge (1) at the center  of the longest free

length and check the tension. The correct tension

is 535 N (120 lb). If the tension of the belt is below

250 N (56 lb) adjust the belt to 535 N (120 lb).

If twin belts are  installed, check and adjust the

tension on both belts.

Adjustment

i01929797

Alternator and Fan  Belts -

Inspect/Adjust/Replace

Inspection

To maximize the engine performance, inspect the

belts for wear and for cracking. Replace belts that are

worn or damaged.

g01003939

Illustration 21

1.  Loosen The alternator pivot bolt (2) and the bolt

(3).

This document has been printed from SPI². Not for Resale

 

SEBU8352

49

Maintenance Section

Battery - Replace

2.  Move the alternator in order  to increase or

decrease the belt tension. Tighten the alternator

pivot bolt and the link bolt to 22 N·m (16 lb ft).(1).

5.  Remove the used battery.

6.  Install the new battery.

Replacement

Note: Before the cables are connected, ensure that

the engine start switch is OFF.

Refer to the Disassembly and Assembly Manual for

the installation procedure and the removal procedure

for the belt.

7.  Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.

8.  Connect the NEGATIVE “-” cable to the NEGATIVE

“-” battery terminal.

i02322315

Battery - Replace

i02747977

Battery Electrolyte Level  -

Check

Batteries give  off combustible  gases which  can

explode. A spark can cause the combustible gas-

es to ignite. This can result in severe personal in-

jury or death.

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.

Ensure proper ventilation for batteries that are in

an enclosure. Follow the proper procedures in or-

der to  help prevent electrical arcs  and/or sparks

near batteries.  Do not smoke when  batteries are

serviced.

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.

The battery cables or the batteries  should not be

removed with the battery cover in place. The bat-

tery cover should be  removed before any servic-

ing is attempted.

1.  Remove the filler caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion

resulting in personal injury.

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.

1.  Switch the engine to the OFF position. Remove

all electrical loads.

2.  Check the condition of the electrolyte  with a

suitable battery tester.

2.  Turn off any battery chargers. Disconnect any

battery chargers.

3.  Install the caps.

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.  Keep the batteries clean.

Clean the battery case with one of the following

cleaning solutions:

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.

•  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.

Note: Always recycle a battery.  Never discard a

battery. Dispose of used batteries to an appropriate

recycling facility.

Thoroughly rinse the battery case with clean water.

This document has been printed from SPI². Not for Resale

 

50

SEBU8352

Maintenance Section

Battery or Battery Cable - Disconnect

i02323088

i02203590

Battery or Battery  Cable -

Disconnect

Cooling System  Coolant

(Commercial Heavy-Duty) -

Change

NOTICE

The battery cables or the batteries  should not be

removed with the battery cover in place. The bat-

tery cover should be  removed before any servic-

ing is attempted.

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion

resulting in personal injury.

Dispose of all fluids according to Local regulations and

mandates.

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

ignition switch (if equipped) to the OFF position

and remove the key and all electrical loads.

NOTICE

Keep all parts clean from contaminants.

2.  Disconnect the negative battery terminal. Ensure

that the cable cannot contact the terminal. When

four 12 volt batteries are involved, two negative

connection must be disconnected.

Contaminants may cause  rapid wear and  shortened

component life.

Clean the cooling system  and flush the cooling

system before the recommended  maintenance

interval if the following conditions exist:

3.  Remove the positive connection.

4.  Clean all disconnected connection and battery

terminals.

•  The engine overheats frequently.

•  Foaming is observed.

5.  Use a fine grade of  sandpaper to clean the

terminals and the cable clamps. Clean the items

until the surfaces are bright or shiny.  DO NOT

remove material excessively. Excessive removal

of material can  cause the clamps to not  fit

correctly. Coat the clamps and the terminals with

a suitable silicone lubricant or petroleum jelly.

•

The oil has entered the cooling system  and the

coolant is contaminated.

•

The fuel has entered the cooling system and the

coolant is contaminated.

6.  Tape the cable connections in  order to help

prevent accidental starting.

Note: When the cooling system  is cleaned, only

clean water is needed.

7.  Proceed with necessary system repairs.

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.

8.  In order to connect the  battery, connect the

positive connection before the negative connector.

Drain

Pressurized System: Hot coolant  can cause seri-

ous 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 pres-

sure.

This document has been printed from SPI². Not for Resale

 

SEBU8352

51

Maintenance Section

Cooling System Coolant (Commercial Heavy-Duty) - Change

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

Loosen the cooling system filler  cap slowly in

order to relieve any pressure. Remove the cooling

system filler cap.

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

Loosen the cooling system filler cap  slowly in

order to relieve any pressure. Remove the cooling

system filler cap. Open the drain cock or remove

the drain plug on the engine. Open the drain cock

or remove the drain plug on the  radiator. Allow

the water to drain. Flush the cooling system with

clean water.

Fill

1.  Close the drain cock or install the drain plug on 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.

g01003928

Illustration 22

Cooling system air locks may result in engine damage.

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

on the engine. Open the drain cock or remove the

drain plug on the radiator.

2.  Fill the cooling  system with Commercial

Heavy-Duty Coolant. Add Supplemental Coolant

Additive to the coolant. For the correct amount,

refer to the Operation and Maintenance Manual,

“Fluid Recommendations” topic (Maintenance

Section) for more information on cooling system

specifications. Do not install the cooling system

filler cap.

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.

3.  Start and run the engine at low idle. Increase the

engine rpm to high idle. Run the engine at high

idle for one minute in order to purge the air from

the cavities of the engine block. Stop the engine.

For information regarding the  disposal and the

recycling of used coolant, consult your Perkins dealer

or your Perkins distributor.

4.  Check the coolant level. Maintain the coolant level

within 13 mm (0.5 inch) below the bottom of the

pipe for filling. Maintain the coolant level  in the

expansion bottle (if equipped) at the correct level.

Flush

1.  Flush the cooling system with clean water in order

to remove any debris.

5.  Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If

the gasket that is on the cooling system filler cap

is damaged, discard the old cooling system filler

cap and install a new cooling system filler cap. If

the gasket that is on the cooling system filler cap

is not damaged, use a suitable pressurizing pump

in order to pressure test the cooling system filler

cap. The correct pressure for the cooling system

filler cap is stamped on the face  of the cooling

system filler cap. If the cooling system filler cap

does not retain the correct pressure, install a new

cooling system filler cap.

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.

3.  Fill the cooling system with clean water. Install the

cooling system filler cap.

6.  Start the engine. Inspect the cooling system for

leaks and for correct operating temperature.

4.  Start and run the engine at  low idle until the

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

This document has been printed from SPI². Not for Resale

 

52

SEBU8352

Maintenance Section

Cooling System Coolant (ELC) - Change

i02203595

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

Loosen the cooling system filler cap  slowly in

order to relieve any pressure. Remove the cooling

system filler cap.

Cooling System Coolant (ELC)

- Change

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before  open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids according to Local regulations and

mandates.

g01003928

Illustration 23

NOTICE

Keep all parts clean from contaminants.

Typical example

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

on the engine. Open the drain cock or remove the

drain plug on the radiator.

Contaminants may cause  rapid wear and  shortened

component life.

Clean the cooling system  and flush the cooling

system before the recommended  maintenance

interval if the following conditions exist:

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.

•  The engine overheats frequently.

•  Foaming is observed.

•  The oil has entered the cooling system  and the

coolant is contaminated.

For information regarding the  disposal and the

recycling of used coolant, consult your Perkins dealer

or your Perkins distributor.

•  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.

Flush

1.  Flush the cooling system with clean water in order

to remove any debris.

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.

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

Drain

(1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

Pressurized System: Hot coolant  can cause seri-

ous 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 pres-

sure.

3.  Fill the cooling system with clean water. Install the

cooling system filler cap.

4.  Start and run the engine  at low idle until the

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

This document has been printed from SPI². Not for Resale

 

SEBU8352

53

Maintenance Section

Cooling System Coolant Extender (ELC) - Add

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

Loosen the cooling system filler  cap slowly in

order to relieve any pressure. Remove the cooling

system filler cap. Open the drain cock or remove

the drain plug on the engine. Open the drain cock

or remove the drain plug on the radiator. Allow

the water to drain. Flush the cooling system with

clean water.

i02335364

Cooling System  Coolant

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.

Fill

1.  Close the drain cock or install the drain plug on the

engine. Close the drain cock or install the drain

plug on the radiator.

Check the cooling system only when the engine is

stopped and cool.

1.  Loosen the cooling system filler cap slowly in

order to relieve pressure. Remove the  cooling

system filler cap.

NOTICE

Do  not   fill  the   cooling  system   faster  than   5  L

(1.3 US gal) per minute to avoid air locks.

2.  It may be necessary to drain enough coolant from

the cooling system in order to add the Extender.

Cooling system air locks may result in engine damage.

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.

2.  Fill the cooling system  with Extended Life

Coolant (ELC). Refer  to the Operation and

Maintenance Manual, “Fluid Recommendations”

topic (Maintenance Section) for more information

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 one minute in order to purge the air from

the cavities of the engine block. Stop the engine.

4.  Clean the cooli, ng 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.

4.  Check the coolant level. Maintain the coolant level

within 13 mm (0.5 inch) below the bottom of the

pipe for filling. Maintain the coolant level 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 gasket that is on the cooling system filler cap

is damaged, discard the old cooling system filler

cap and install a new cooling system filler cap. If

the gasket that is on the cooling system filler cap

is not damaged, use a suitable pressurizing pump

in order to pressure test the cooling system filler

cap. The correct pressure for the cooling system

filler cap is stamped on the face  of the cooling

system filler cap. If the cooling system filler cap

does not retain the correct pressure, install a new

cooling system filler cap.

i02335378

Cooling System Coolant Level

- Check

Engines With a Coolant Recovery

Tank

Note: The cooling system  may not have been

provided by Perkins. The procedure  that follows

is for typical cooling systems.  Refer to the OEM

information for the correct procedures.

6.  Start the engine. Inspect the cooling system for

leaks and for correct operating temperature.

Check the coolant level when the engine is stopped

and cool.

This document has been printed from SPI². Not for Resale

 

54

SEBU8352

Maintenance Section

Driven Equipment - Check

1.  Observe the coolant level in the coolant recovery

tank. Maintain the coolant level to “COLD FULL”

mark on the coolant recovery tank.

Pressurized System: Hot coolant  can cause seri-

ous 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 pres-

sure.

2.  Loosen filler cap slowly in order to relieve any

pressure. Remove the filler cap.

g00285520

Illustration 25

Cooling system filler cap

3.  Pour the correct coolant mixture into the tank.

Refer to the Operation and Maintenance Manual,

“Refill Capacities and Recommendations” for

information on the correct mixture and  type of

coolant. Refer to the Operation and Maintenance

Manual, “Refill Capacities and Recommendations”

for the cooling system capacity. Do  not fill the

coolant recovery tank above “COLD FULL” mark.

Pressurized System: Hot coolant  can cause seri-

ous 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 pres-

sure.

1.  Remove the cooling system filler cap slowly in

order to relieve pressure.

2.  Maintain the coolant level within 13 mm (0.5 inch)

of the bottom of the filler  pipe. If the engine is

equipped with a sight glass, maintain the coolant

level to the correct level in the sight glass.

3.  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.

g00103639

Illustration 24

4.  Clean filler cap and the receptacle. Reinstall the

filler cap and inspect the cooling system for leaks.

Note: The coolant will expand as the coolant heats

up during normal engine operation. The additional

volume will be forced into the coolant recovery tank

during engine operation. When the engine is stopped

and cool, the coolant will return to the engine.

4.  Inspect the cooling system for leaks.

i00174798

Driven Equipment - Check

Engines Without  a Coolant

Recovery Tank

Refer to the OEM specifications for more information

on the following maintenance recommendations for

the driven equipment:

Check the coolant level when the engine is stopped

and cool.

•  Inspection

•  Adjustment

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SEBU8352

55

Maintenance Section

Engine - Clean

•  Lubrication

i01915869

Engine Air Cleaner Element

(Dual Element) - Clean/Replace

•  Other maintenance recommendations

Perform any maintenance for the driven equipment

which is recommended by the OEM.

NOTICE

i01930350

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 air-

borne debris from entering the air inlet.

Engine - Clean

Personal injury or death can result from high volt-

age.

NOTICE

Never service the air cleaner element with the engine

running since this will allow dirt to enter the engine.

Moisture can create paths of electrical conductiv-

ity.

Make sure that the electrical system is OFF. Lock

out the starting controls and tag the controls “DO

NOT OPERATE”.

Servicing the Air Cleaner Elements

Note: The air filter  system may not have been

provided by Perkins. The procedure  that follows

is for a typical air filter system.  Refer to the OEM

information for the correct procedure.

NOTICE

Accumulated grease and oil on an engine is a fire haz-

ard. Keep the engine clean. Remove debris and fluid

spills whenever a significant quantity accumulates on

the engine.

If the air cleaner element becomes plugged, the air

can split the material of  the air cleaner element.

Unfiltered air will drastically  accelerate internal

engine wear. Refer to the OEM information for the

correct air cleaner elements for your application.

NOTICE

Failure  to  protect  some  engine  components  from

washing  may  make  your  engine  warranty  invalid.

Allow the engine to cool for one hour before washing

the engine.

•  Check the precleaner (if equipped) and the dust

bowl daily for accumulation of  dirt and debris.

Remove any dirt and debris, as needed.

•  Operating conditions (dust, dirt and debris) may

require more frequent service of the air  cleaner

element.

Periodic cleaning of the engine is recommended.

Steam cleaning the engine will remove accumulated

oil and grease. A clean engine provides the following

benefits:

•  The air cleaner element should be replaced at least

one time per year. This replacement  should be

performed regardless of the number of cleanings.

•  Easy detection of fluid leaks

•  Maximum heat transfer characteristics

•  Ease of maintenance

Replace the dirty air cleaner elements with clean air

cleaner elements. Before installation, the air cleaner

elements should be thoroughly checked for tears

and/or holes in the filter material. Inspect the gasket

or the seal of the air cleaner element for  damage.

Maintain a supply of suitable air cleaner elements

for replacement purposes.

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.

This document has been printed from SPI². Not for Resale

 

56

SEBU8352

Maintenance Section

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

Cleaning the Primary Air Cleaner

Dual Element Air Cleaners

Elements

The dual element air cleaner contains a primary air

cleaner element and a secondary air cleaner element.

The primary air cleaner element can  be used up

to six times if the element is properly cleaned  and

properly inspected. 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.

NOTICE

Observe  the following  guidelines  if  you  attempt to

clean the filter element:

Do not  tap or strike the  filter element in  order to re-

move dust.

Do not wash the filter element.

The secondary air cleaner element is not serviceable

or washable. Refer to  the OEM information for

instructions in order to replace the  secondary air

cleaner element. When the engine is operating in

environments that are dusty or  dirty, air cleaner

elements may require more frequent replacement.

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.

Refer to the OEM information in order to determine

the number of times that the primary filter element can

be cleaned. 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.

g00736431

Illustration 26

NOTICE

(1) Cover

Do not clean the air cleaner elements by bumping  or

tapping. This could damage the seals. Do not use el-

ements with damaged pleats, gaskets or seals. Dam-

aged elements will allow dirt to pass through. Engine

damage could result.

(2) Primary air cleaner element

(3) Secondary air cleaner element

(4) Air inlet

1.  Remove the cover. Remove the  primary air

cleaner element.

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.

2.  The secondary air cleaner element should be

removed and discarded for every three cleanings

of the primary air cleaner element.

Note: Refer to “Cleaning the Primary Air  Cleaner

Elements”.

There are two common methods that are used  to

clean primary air cleaner elements:

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

out.

•  Pressurized air

•  Vacuum cleaning

4.  Clean the inside of the air cleaner cover and body

with a clean, dry cloth.

Pressurized Air

5.  Remove the tape for the air  inlet. Install the

secondary air cleaner element. Install a primary

air cleaner element that is new or cleaned.

Pressurized air can be used to  clean primary air

cleaner elements that have not been cleaned more

than two times. Pressurized  air will not remove

deposits of carbon and oil. Use filtered, dry air with a

maximum pressure of 207 kPa (30 psi).

6.  Install the air cleaner cover.

7.  Reset the air cleaner service indicator.

This document has been printed from SPI². Not for Resale

 

SEBU8352

57

Maintenance Section

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

Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar

facility. Place the blue light in the primary air cleaner

element. Rotate the primary air cleaner  element.

Inspect the primary air cleaner element  for tears

and/or holes. Inspect the primary air cleaner element

for light that may show through the filter material. If it

is necessary in order to confirm the result, compare

the primary air cleaner element to a new primary air

cleaner element that has the same part number.

Do not use a primary air cleaner element that has

any tears and/or holes in the filter material. Do not

use a primary air cleaner element  with damaged

pleats, gaskets or seals. Discard damaged primary

g00281692

Illustration 27

air cleaner elements.

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).

i02152042

Engine  Air Cleaner

Element (Single Element)  -

Inspect/Replace

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.

Refer to Operation and Maintenance Manual, “Engine

Air Cleaner Service Indicator-Inspect”.

Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.

NOTICE

Vacuum Cleaning

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 air-

borne debris from entering the air inlet.

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.

NOTICE

Never service the air cleaner element with the engine

running since this will allow dirt to enter the engine.

Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.

Inspecting the Primary  Air Cleaner

Elements

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.

i01909507

Engine Air Cleaner Service

Indicator - Inspect

Some engines may be equipped  with a different

service indicator.

g00281693

Illustration 28

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58

SEBU8352

Maintenance Section

Engine Mounts - Inspect

Some engines are equipped with a differential gauge

for inlet air pressure. The differential gauge for inlet

air pressure displays the difference in the pressure

that is measured before the air cleaner element and

the pressure that is measured after the air cleaner

element. As the air cleaner element becomes dirty,

the pressure differential rises.  If your engine is

equipped with a different type of service indicator,

follow the OEM recommendations in order to service

the air cleaner service indicator.

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:

The service indicator may be mounted  on the air

cleaner element or in a remote location.

•  Incorrect mounting of the engine

•  Deterioration of the engine mounts

•  Loose engine mounts

Any engine mount that shows deterioration should

be replaced. Refer to the OEM information for the

recommended torques.

i02676018

Engine Oil Level - Check

g00103777

Illustration 29

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:

Hot oil and  hot components can  cause personal

injury. Do not allow hot  oil or hot components to

contact the skin.

•  The yellow diaphragm enters the red zone.

•  The red piston locks in the visible position.

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 approximately at the

greatest vacuum that is attained.

g01165836

Illustration 30

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.

(Y) “MIN” mark. (X) “MAX” mark.

NOTICE

Perform this maintenance with the engine stopped.

The service indicator may  need to be replaced

frequently in environments that are severely dusty.

Note: Ensure that the engine is either level or that

the engine is in the normal operating position in order

to obtain a true level indication.

This document has been printed from SPI². Not for Resale

 

SEBU8352

59

Maintenance Section

Engine Oil Sample - Obtain

Note: After the engine has been switched OFF, allow

the engine oil to drain to the oil pan before checking

the oil level.

•  Engine number

•  Service hours on the engine

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

and the “MAX” mark (X) on the engine oil dipstick.

Do not fill the crankcase above the “MAX” mark

(X).

•  The number of hours that have accumulated since

the last oil change

•  The amount of oil that has been added since the

last oil change

NOTICE

Ensure that the container for the sample is clean and

dry. Also ensure that the container for the sample is

clearly labelled.

Operating your engine when the oil level is above the

“FULL” mark could cause  your crankshaft to dip into

the oil.  The air bubbles  created from the  crankshaft

dipping into the oil  reduces the oil’s lubricating char-

acteristics and could result in the loss of power.

To ensure that the sample is representative of the

oil in the crankcase, obtain a warm, well mixed oil

sample.

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

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

To avoid contamination of the oil samples, the tools

and the supplies that  are used for obtaining oil

samples must be clean.

i02202699

Engine Oil Sample - Obtain

The sample can be checked for the following: the

quality of the oil, the existence of any coolant in the

oil, the existence of any ferrous metal  particles in

the oil, and the existence of any nonferrous metal

particles in the oil.

The condition of the engine lubricating oil may  be

checked at regular intervals as part of a preventive

maintenance program. Perkins  include an oil

sampling valve as an option. The oil sampling valve

(if equipped) is included in order to regularly sample

the engine lubricating oil. The oil sampling valve is

positioned on the oil filter head or the oil sampling

valve is positioned on the cylinder block.

i02703306

Engine Oil and Filter - Change

Perkins recommends using a sampling valve in order

to obtain oil samples. The quality and the consistency

of the samples are better when a sampling valve is

used. The location of the sampling valve allows oil

that is flowing under pressure to be obtained during

normal engine operation.

Hot oil  and hot components can  cause personal

injury. Do not allow hot  oil or hot components to

contact the skin.

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

properly.

Obtain the Sample and the Analysis

Hot oil  and hot components can  cause personal

injury. Do not allow  hot oil or hot components to

contact the skin.

Failure to follow this recommended procedure will

cause the waste particles to be recirculated through

the engine lubrication system with the new oil.

In order to help obtain the most accurate analysis,

record the following information before an oil sample

is taken:

•  The date of the sample

•  Engine model

This document has been printed from SPI². Not for Resale

 

60

SEBU8352

Maintenance Section

Engine Oil and Filter - Change

Drain the Engine Oil

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.

g01356033

Illustration 31

Oil drain plug

After the engine has been run at the normal operating

temperature, stop the  engine. Use one of the

following methods to drain the engine crankcase oil:

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

drain valve knob counterclockwise in order to drain

the oil. After the oil has drained, turn the drain valve

knob clockwise in order to close the drain valve.

•  If the engine is not equipped with a  drain valve,

remove the oil drain plug (1) in order to allow the

oil to drain. If the engine is equipped with a shallow

sump, remove the bottom oil drain plugs from both

ends of the oil pan.

After the oil has drained, the oil drain plugs should

be cleaned and installed. If necessary, renew the O

ring seal on the drain plug.

Some types of oil pans have oil drain plugs that are

on both sides of the oil pan, because of the shape of

the pan. This type of oil pan requires the engine oil to

be drained from both plugs.

g01356034

Illustration 32

(2) Filter head

(3) O ring seal

Replace the Spin-on Oil Filter

3.  Clean the sealing surface of the oil filter head (2).

Ensure that the union (4) in the oil filter head is

secure.

NOTICE

Perkins oil filters are  manufactured to Perkins speci-

fications. Use of an oil filter that is not recommended

by Perkins could  result in severe damage  to the en-

gine 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.

4.  Apply clean engine oil to the O ring seal (3) on

the oil filter.

This document has been printed from SPI². Not for Resale

 

SEBU8352

61

Maintenance Section

Engine Valve Lash - Inspect/Adjust

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

IDLE” for two minutes. Perform this procedure in

order to ensure that the lubrication system has

oil and that the oil filters are filled. Inspect the oil

filter for oil leaks.

NOTICE

Do not fill the oil filters with oil before  installing them.

This oil would not be filtered and could be contaminat-

ed. Contaminated oil can  cause accelerated wear to

engine components.

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

the sump for a minimum of ten minutes.

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

according to the instructions that are shown on

the oil filter. Do not overtighten the oil filter.

Note: Some oil filters may be  installed vertically.

Refer to illustration 33. Start at step (1) in order  to

remove the oil filter and install the oil filter.

g01165836

Illustration 34

(Y) “MIN” mark. (X) “MAX” mark.

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 engine oil dipstick.

i02171102

Engine Valve  Lash  -

Inspect/Adjust

g01356074

Illustration 33

Typical example

This maintenance is recommended by Perkins as

part of a lubrication and preventive  maintenance

schedule in order to help provide maximum engine

life.

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

proper amount of oil. Refer to the Operation and

Maintenance Manual for more information on refill

capacities.

NOTICE

Only qualified  service  personel should  perform this

maintenance. Refer to the Service Manual or your au-

thorized Perkins dealer or your Perkins distributor for

the complete valve lash adjustment procedure.

NOTICE

Operation of Perkins engines with incorrect valve lash

can reduce engine efficiency, and also reduce engine

component life.

If equipped with  an auxiliary oil filter system  or a re-

mote oil filter system,  follow the OEM or filter  manu-

facturer’s recommendations. Under filling or overfilling

the crankcase with oil can cause engine damage.

NOTICE

To prevent crankshaft bearing damage, crank the en-

gine with the fuel OFF. This will fill the oil filters before

starting the engine. Do not crank the engine for more

than 30 seconds.

This document has been printed from SPI². Not for Resale

 

62

SEBU8352

Maintenance Section

Fuel Injector - Test/Change

Ensure that  the engine  can not be  started while

this maintenance is being performed. To help pre-

vent 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 mea-

suring/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.

i02198352

Fuel Injector - Test/Change

g01110422

Illustration 35

Typical fuel Injectors

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.

The fuel injector (1) will need to be removed and the

injector will need to be checked for performance.

NOTICE

The fuel injectors should not be cleaned as cleaning

with incorrect tools can damage the nozzle. The fuel

injectors should be renewed only if a fault with the

fuel injectors occurs. Some of the problems that may

indicate that new fuel injectors are needed are listed

below:

Do not allow dirt to enter the fuel system. Thoroughly

clean the area around a  fuel system component that

will be disconnected. Fit a suitable cover over discon-

nected fuel system component.

NOTICE

•  The engine will not start or the engine is difficult

If a fuel  injector is suspected of operating  outside of

normal parameters it should be removed by a qualified

technician. The suspect fuel injector should be  taken

to an authorised agent for inspection.

to start.

•  Not enough power

•  The engine misfires or the engine runs erratically.

•  High fuel consumption

The fuel injector (1) in  illustration 35 has no fuel

return. The fuel injector (2) has a fuel return.

•  Black exhaust smoke

•  The engine knocks or there  is vibration in the

engine.

•  Excessive engine temperature

This document has been printed from SPI². Not for Resale

 

SEBU8352

63

Maintenance Section

Fuel System - Prime

Removal and Installation of  the

Fuel Injectors

Use the following procedure in order to remove air

from the fuel system:

1.  Ensure that all fuel connections are  installed

correctly.

2.  Turn the keyswitch to the RUN position. Leave the

keyswitch in the RUN position for three minutes.

If a manual purging screw is installed,  slacken

the manual purging screw during priming the fuel

system.

Work carefully around an  engine that is running.

Engine parts that are hot, or parts that are moving,

can cause personal injury.

3.  Crank the engine with the throttle lever  in the

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.

closed position until the engine starts.

NOTICE

If your skin comes into contact with high pressure fuel,

obtain medical assistence immediately.

Operate the engine at a fast idle speed in order to

identify the faulty fuel injector. Individually loosen and

tighten the union nut for the high pressure pipe  to

each fuel injector. Do not loosen the union nut more

than half a turn. There will be little effect on the engine

speed when the union nut to the faulty fuel injection

nozzle is loosened. Refer to the Disassembly and

Assembly Manual for more information. Consult your

authorized Perkins dealer or your Perkins distributor

for assistance.

g01228000

Illustration 36

Injector nuts

Note: If necessary, loosen the union nuts (1) on the

fuel injection lines at the connection with  the fuel

injector until fuel is evident. Stop cranking the engine.

Tighten the union nuts to a torque of 27 N·m (20 lb ft).

4.  Start the engine and run the engine at idle for one

minute.

i02869449

5.  Cycle the throttle lever from the low idle position to

the high idle position three times. The cycle time

for the throttle lever is approximately one second

to six seconds for one complete cycle.

Fuel System - Prime

Note: In order to purge air from  the fuel injection

pump on Perkins engines with a fixed throttle, the

engine should be run at full load for thirty seconds.

This should be repeated three times. This will assist

in removing trapped air from the fuel injection pump.

If air enters the fuel system, the air must be purged

from the fuel system  before the engine can be

started. Air can enter  the fuel system when the

following events occur:

•  The fuel tank is empty or the fuel tank has been

partially drained.

6.  Return the engine to no load condition. Check for

leaks in the fuel system.

•  The low pressure fuel lines are disconnected.

•  A leak exists in the low pressure fuel system.

•  The fuel filter is replaced.

•  A new injection pump is installed.

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64

SEBU8352

Maintenance Section

Fuel System Primary Filter/Water Separator - Drain

i02873783

Fuel System  Primary

Filter/Water Separator - Drain

Fuel leaked or  spilled onto hot  surfaces or elec-

trical components  can cause a  fire. To help  pre-

vent possible injury, turn the start switch off when

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

NOTICE

The water separator is not a filter. The water separa-

tor separates water from the fuel.  The engine should

never be allowed to run with the water separator more

than half full. Engine damage may result.

NOTICE

The water  separator is under  suction during  normal

engine operation. Ensure that the drain valve is tight-

ened securely to help prevent air from entering the fuel

system.

g01118416

Illustration 37

(1) Screw

(2) Element

(3) Glass bowl

(4) Sensor connection

(5) Drain

(6) Bottom cover

1.  Place a suitable container below  the water

separator.

2.  Open the drain (5). Allow the fluid to drain into

the container.

3.  When clean fuel drains from the water separator

close the drain (5). Tighten  the drain by hand

pressure only. Dispose  of the drained fluid

correctly.

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SEBU8352

65

Maintenance Section

Fuel System Primary Filter (Water Separator) Element - Replace

i02875191

1.  Turn the fuel supply valve (if equipped) to the OFF

position.

Fuel System Primary  Filter

(Water Separator) Element -

Replace

2.  Place a suitable container under  the water

separator. Clean the  outside of the  water

separator.

3.  Open the drain (5). Allow the fluid to drain into

the container.

4.  Tighten the drain (5) by hand pressure only.

Fuel leaked or  spilled onto hot  surfaces or elec-

trical components  can cause a  fire. To help  pre-

vent possible injury, turn the start switch off when

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

5.  Hold the element (2) and remove the screw (1).

Remove the element and the glass bowl (3) from

the base. Discard the old element.

6.  Clean the glass bowl (4). Clean the bottom cover

(6).

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly

clean the area around a  fuel system component that

will be disconnected. Fit a suitable cover over discon-

nected fuel system component.

7.  Install the new O ring seal. Install the bottom cover

onto the new element. Install the assembly onto

the base.

8.  Install the screw (1) and tighten the screw to a

torque of 8 N·m (6 lb ft).

9.  Remove the container and dispose of the fuel

safely.

10. Open the fuel supply valve.

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

Maintenance Manual, “Fuel System - Prime” for

more information.

i02873572

Fuel System Secondary Filter -

Replace

Fuel leaked  or spilled onto hot  surfaces or elec-

trical components  can cause a  fire. To help  pre-

vent possible injury, turn the start switch off when

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

g01118416

Illustration 38

NOTICE

Typical example

Do not allow dirt to enter the fuel system. Thoroughly

clean the area around a  fuel system component that

will be disconnected. Fit a suitable cover over discon-

nected fuel system component.

(1) Screw

(2) Element

(3) Glass bowl

(4) Sensor connection

(5) Drain

(6) Bottom cover

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66

SEBU8352

Maintenance Section

Hoses and Clamps - Inspect/Replace

Spin-on filter

Turn the valves for the fuel lines (if equipped) to the

OFF position before performing this maintenance.

Place a tray under the fuel  filter in order to catch

any fuel that might spill. Clean up any  spilled fuel

immediately.

g01440510

Illustration 40

Typical example

4.  Lubricate the sealing ring (4) with clean fuel oil.

5.  Install the spin-on filter (2) into the top of the fuel

priming pump (1).

6.  Tighten the spin-on filter by hand until the sealing

ring contacts the fuel priming pump. Rotate the

spin-on filter through 90 degrees.

7.  Prime the fuel system. Refer to Operation and

Maintenance Manual, “Fuel System - Prime”.

g01440509

Illustration 39

Typical example

i02813964

Hoses and  Clamps  -

Inspect/Replace

(1) Fuel priming pump

(2) Spin-on filter

(3) Drain

1.  Clean the outside of the fuel filter assembly. Open

the fuel drain (3) and drain the fuel into a suitable

container.

Inspect all hoses for leaks that are caused  by the

following conditions:

2.  Use a suitable tool in order to remove the spin-on

filter (2) from the fuel priming pump (1).

•  Cracking

3.  Ensure that the fuel drain (3) on the new spin-on

filter is closed.

•  Softness

•  Loose clamps

Replace hoses that are cracked or soft. Tighten any

loose clamps.

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SEBU8352

67

Maintenance Section

Radiator - Clean

NOTICE

Do not bend or  strike high pressure lines. Do  not in-

stall 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 rec-

ommended torque. Do  not clip any other item  to the

high pressure lines.

Pressurized System: Hot coolant  can cause seri-

ous 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 pres-

sure.

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

Check for the following conditions:

2.  Loosen the cooling system filler cap slowly in

order to relieve any pressure. Remove the cooling

system filler cap.

•  End fittings that are damaged or leaking

•  Outer covering that is chafed or cut

Note: Drain the  coolant into a suitable, clean

container. The coolant can be reused.

•  Exposed wire that is used for reinforcement

•  Outer covering that is ballooning locally

•  Flexible part of the hose that is kinked or crushed

•  Armoring that is embedded in the outer covering

3.  Drain the coolant from the cooling system to a

level that is below the hose that is being replaced.

4.  Remove the hose clamps.

5.  Disconnect the old hose.

A constant torque hose clamp can be used in place

of any standard hose clamp. Ensure that the constant

torque hose clamp is the same size as the standard

clamp.

6.  Replace the old hose with a new hose.

7.  Install the hose clamps with a torque wrench.

Due to extreme temperature changes, the hose will

harden. Hardening of the hoses  will cause hose

clamps to loosen. This can result in leaks. A constant

torque hose clamp will help to prevent loose hose

clamps.

Note: For the correct coolant, see this Operation and

Maintenance Manual, “Fluid Recommendations”.

8.  Refill the cooling system. Refer  to the OEM

information for further information on refilling the

cooling system.

Each installation application can be different. The

differences depend on the following factors:

9.  Clean the cooling system filler cap. Inspect the

cooling system filler cap’s seals.  Replace the

cooling system filler cap if the seals are damaged.

Install the cooling system filler cap.

•  Type of hose

•  Type of fitting material

10. Start the engine. Inspect the cooling system for

leaks.

•  Anticipated expansion and contraction of the hose

•  Anticipated expansion and contraction  of the

fittings

i02335774

Radiator - Clean

Replace the Hoses and the Clamps

Refer to the OEM information for further information

on removing and replacing fuel hoses (if equipped).

The radiator is not usually supplied by Perkins. The

following text describes a typical cleaning procedure

for the radiator. Refer to the OEM  information for

further information on cleaning the radiator.

The coolant system and the hoses for the coolant

system are not usually supplied  by Perkins. The

following text describes a typical method of replacing

coolant hoses. Refer to the OEM  information for

further information on the coolant system and the

hoses for the coolant system.

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

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68

SEBU8352

Maintenance Section

Severe Service Application - Check

Inspect the radiator for these items: Damaged fins,

corrosion, dirt, grease, insects, leaves, oil, and other

debris. Clean the radiator, if necessary.

i02335775

Severe Service Application -

Check

Personal injury can result from air pressure.

Severe service is the application of an engine that

exceeds the current published standards for  that

engine. Perkins maintains standards for the following

engine parameters:

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-

tective face shield and protective clothing.

•  Performance such as power range, speed range,

and fuel consumption

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

•  Fuel quality

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction

to the fan’s air flow. Hold the nozzle approximately

6 mm (0.25 inch) away from the radiator fins. Slowly

move the air nozzle in a direction that is parallel with

the radiator tube assembly. This will remove debris

that is between the tubes.

•  Operational Altitude

•  Maintenance intervals

•  Oil selection and maintenance

•  Coolant type and maintenance

•  Environmental qualities

•  Installation

Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes

must be less than 275 kPa (40 psi). Use pressurized

water in order to soften mud. Clean the core  from

both sides.

•  The temperature of the fluid in the engine

Use a degreaser and steam for removal of oil and

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

with detergent and hot water. Thoroughly rinse the

core with clean water.

Refer to the standards for the engine or consult your

Perkins dealer or your Perkins distributor in order to

determine if the engine is operating within the defined

parameters.

If the radiator is blocked internally, refer to the OEM

Manual for information regarding flushing the cooling

system.

Severe service operation can accelerate component

wear. Engines that operate under severe conditions

may need more frequent maintenance intervals in

order to ensure maximum reliability and retention of

full service life.

After cleaning the radiator, start the engine. Allow

the engine to operate at low idle speed for three to

five minutes. Accelerate the engine to high idle. This

will help in the removal of debris and the drying of

the core. Slowly reduce the engine speed to low idle

and then stop the engine. Use a light bulb  behind

the core in order to inspect the core for cleanliness.

Repeat the cleaning, if necessary.

Due to individual applications,  it is not possible

to identify all of the factors  which can contribute

to severe service operation. Consult your Perkins

dealer or your Perkins distributor  for the unique

maintenance that is necessary for the engine.

Inspect the fins for damage. Bent fins may be opened

with a “comb”. Inspect these items for good condition:

Welds, mounting brackets, air lines, connections,

clamps, and seals. Make repairs, if necessary.

The operating environment, incorrect  operating

procedures and incorrect maintenance procedures

can be factors which contribute to a severe service

application.

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SEBU8352

69

Maintenance Section

Starting Motor - Inspect

Environmental Factors

Check the starting motor for correct operation. Check

the electrical connections and clean the electrical

connections. Refer to the Systems Operation, Testing

and Adjusting Manual, “Electric Starting System -

Test” for more information on the checking procedure

and for specifications or consult your Perkins dealer

or your Perkins distributor for assistance.

Ambient temperatures  – The engine may  be

exposed to extended  operation in extremely

cold environments or hot  environments. Valve

components can be damaged by carbon buildup if

the engine is frequently started and stopped in very

cold temperatures. Extremely hot intake air reduces

engine performance.

i02184788

Turbocharger - Inspect

(If Equipped)

Quality of the air  – The engine may be exposed

to extended operation in an  environment that is

dirty or dusty, unless  the equipment is cleaned

regularly. Mud, dirt and dust can encase components.

Maintenance can be very difficult. The buildup can

contain corrosive chemicals.

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.

Buildup  – Compounds, elements, corrosive

chemicals and salt can damage some components.

Altitude  – Problems can arise when the engine is

operated at altitudes that are higher than the intended

settings for that application. Necessary adjustments

should be made.

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.

Incorrect Operating Procedures

•  Extended operation at low idle

•  Frequent hot shutdowns

•  Operating at excessive loads

NOTICE

Turbocharger bearing failures can cause large quanti-

ties of oil to enter the air intake and exhaust systems.

Loss of engine lubricant  can result in serious engine

damage.

•  Operating at excessive speeds

•  Operating outside the intended application

Incorrect Maintenance Procedures

Minor leakage of oil into a turbocharger under extend-

ed low  idle operation should not  cause problems as

long  as a  turbocharger  bearing failure  has  not oc-

cured.

•  Extending the maintenance intervals

•  Failure to use recommended fuel, lubricants and

coolant/antifreeze

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.

i02177969

Starting Motor - Inspect

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.

Perkins recommends a scheduled inspection of the

starting motor. If the starting motor fails, the engine

may not start in an emergency situation.

Removal and Installation

Note: The turbochargers that  are supplied are

nonserviceable.

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70

SEBU8352

Maintenance Section

Walk-Around Inspection

For options regarding the removal, installation, and

replacement, consult your Perkins dealer or your

Perkins distributor. Refer to the Disassembly and

Assembly Manual, “Turbocharger - Remove and

Turbocharger - Install” for further information.

•  The guards must be in the correct place. Repair

damaged guards or replace missing guards.

•  Wipe all caps and  plugs before the engine is

serviced in order to reduce the chance of system

contamination.

Inspecting

NOTICE

For any type of leak (coolant, lube, or fuel) clean up the

fluid. If leaking is observed, find the source and correct

the leak. If leaking is suspected, check the fluid levels

more often than recommended until the leak is found

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

unwarranted.

NOTICE

The compressor  housing for  the turbocharger  must

not be removed from the turbocharger for cleaning.

The actuator linkage is connected to the compressor

housing. If the actuator linkage is moved or disturbed

the engine may not  comply with emmissions legisla-

tion.

NOTICE

Accumulated grease and/or oil on an  engine is a fire

hazard. Remove the accumulated grease and oil. Re-

fer to  this Operation and  Maintenance Manual, “En-

gine - Clean” for more information.

1.  Remove the pipe from the turbocharger exhaust

outlet and remove the  air intake pipe to the

turbocharger. Visually inspect the piping for the

presence of oil. Clean the interior  of the pipes

in order to prevent  dirt from entering during

reassembly.

•  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.

2.  Check for the presence of oil. If oil is leaking from

the back side of the compressor wheel, there is a

possibility of a failed turbocharger oil seal.

•  Inspect the water pump for coolant leaks.

The presence of oil may be the result of extended

engine operation at low idle. The presence of oil

may also be the result of a restriction of the line

for the intake air (clogged air filters), which causes

the turbocharger to slobber.

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.

3.  Inspect the bore of the housing of  the turbine

outlet for corrosion.

4.   Fasten the air intake pipe and the exhaust outlet

pipe to the turbocharger housing.

i02177973

•  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.

Walk-Around Inspection

•  Inspect the fuel system for leaks. Look for loose

fuel line clamps and/or tie-wraps.

Inspect the Engine for Leaks and

for Loose Connections

•

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.

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.

•  Inspect the alternator belts and any accessory

drive belts for cracks, breaks or other damage.

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:

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SEBU8352

71

Maintenance Section

Water Pump - Inspect

Belts for multiple groove pulleys must be replaced as

matched sets. If only one belt is replaced, the belt will

carry more load than the belts that are not replaced.

The older belts are stretched. The additional load on

the new belt could cause the belt to break.

•  Drain the water and the sediment from  the fuel

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 condition.

•  Disconnect any battery chargers  that are not

protected against the current drain of the starting

motor. Check the condition and the electrolyte level

of the batteries, unless the engine is equipped with

a maintenance free battery.

•  Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that

can not be calibrated.

i01907756

Water Pump - Inspect

A failed water pump  may cause severe engine

overheating problems that could result in the following

conditions:

•  Cracks in the cylinder head

•  A piston seizure

•  Other potential damage to the engine

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 parts contract.

Visually inspect the water pump for leaks. Renew

the water pump seal or  the water pump if there

is an excessive leakage of  coolant. Refer to the

Disassembly and Assembly Manual, “Water Pump

- Remove and Install”  for the disassembly and

assembly procedure.

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72

SEBU8352

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 prescribed  by the law at  the time of

manufacture, and this engine may be covered by an

Emissions Warranty. Consult your authorized Perkins

dealer or your authorized Perkins distributor in order

to determine if your engine is emissions certified and

if your engine is subject to an Emissions Warranty.

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SEBU8352

73

Index Section

Index

A

E

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

After Stopping Engine............................................ 28

Aftercooler Core - Clean/Test................................  47

Aftercooler Core - Inspect...................................... 47

Alternator - Inspect ................................................ 48

Alternator and  Fan Belts -  Inspect/Adjust/

Replace................................................................ 48

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

Inspection........................................................... 48

Replacement......................................................  49

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

Grounding Practices .......................................... 12

Emergency Stopping.............................................  28

Emissions Certification Film .................................. 18

Emissions Warranty Information............................ 72

Engine - Clean....................................................... 55

Engine Air Cleaner  Element (Dual Element) -

Clean/Replace.....................................................  55

Cleaning the Primary Air Cleaner Elements ...... 56

Servicing the Air Cleaner Elements ................... 55

Engine Air Cleaner Element  (Single Element) -

Inspect/Replace...................................................  57

Engine Air Cleaner Service Indicator - Inspect...... 57

Test the Service Indicator................................... 58

Engine Description ................................................ 14

Engine Cooling and Lubrication.........................  15

Engine Service Life............................................  15

Engine Specifications......................................... 14

Engine Identification..............................................  16

Engine Mounts - Inspect........................................ 58

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

Drain the Engine Oil........................................... 60

Fill the Engine Crankcase..................................  61

Replace the Spin-on Oil Filter ...........................  60

Engine Oil Level - Check.......................................  58

Engine Oil Sample - Obtain................................... 59

Obtain the Sample and the Analysis.................. 59

Engine Operation................................................... 27

Engine Starting................................................. 11, 24

Engine Stopping............................................... 11, 28

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

Engine Warm-up.................................................... 27

B

Battery - Replace................................................... 49

Battery Electrolyte Level - Check .......................... 49

Battery or Battery Cable - Disconnect...................  50

Before Starting Engine .................................... 10, 24

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

Batteries...............................................................  8

Coolant................................................................. 8

Oils.......................................................................  8

C

Cold Weather Operation........................................ 29

Hints for Cold Weather Operation...................... 29

Idling the Engine ................................................ 30

Recommendations for Coolant Warm Up .......... 30

Recommendations for the Coolant .................... 29

Viscosity of the Engine Lubrication Oil............... 29

Cold Weather Starting ........................................... 25

Cooling System Coolant (Commercial Heavy-Duty) -

Change................................................................  50

Drain .................................................................. 50

Fill ...................................................................... 51

Flush .................................................................. 51

Cooling System Coolant (ELC) - Change.............. 52

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

Fill ...................................................................... 53

Flush .................................................................. 52

Cooling System Coolant Extender (ELC) - Add..... 53

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

Engines With a Coolant Recovery Tank............. 53

Engines Without a Coolant Recovery Tank........ 54

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

F

Features and Controls...........................................  23

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

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

Lines, Tubes and Hoses .................................... 10

Fluid Recommendations............................ 33, 38, 42

Cooling System Specifications........................... 33

ELC Cooling System Maintenance .................... 36

Engine Oil .......................................................... 39

Fuel Specifications.............................................  42

General Lubricant Information ........................... 38

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 ................. 31

Fuel Conservation Practices.................................. 27

D

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

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74

SEBU8352

Index Section

Fuel Injector - Test/Change ................................... 62

Removal and Installation of the Fuel Injectors...  63

Fuel Related Components in Cold Weather..........  32

Fuel Filters.........................................................  32

Fuel Heaters ...................................................... 32

Fuel Tanks.......................................................... 32

Fuel Shutoff ........................................................... 23

Fuel System - Prime..............................................  63

Fuel System Primary  Filter (Water Separator)

Product Storage..................................................... 19

Cooling System..................................................  20

Exhaust System.................................................  20

General Items .................................................... 21

Induction System ............................................... 20

Lubrication System ............................................ 19

R

Element - Replace ............................................... 65

Fuel System Primary  Filter/Water Separator -

Drain....................................................................  64

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

Spin-on filter.......................................................  66

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

Reference Numbers .............................................. 17

Record for Reference......................................... 17

Refill Capacities.....................................................  33

Cooling System..................................................  33

Lubrication System ............................................ 33

G

Gauges and Indicators .......................................... 22

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

Containing Fluid Spillage ..................................... 7

Fluid Penetration..................................................  7

Pressure Air and Water........................................ 7

S

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

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

(2) Ether...............................................................  6

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

Serial Number Plate .............................................. 16

Severe Service Application - Check......................  68

Environmental Factors.......................................  69

Incorrect Maintenance Procedures....................  69

Incorrect Operating Procedures......................... 69

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

Starting the Engine................................................  25

Starting with Jump Start Cables............................  26

Stopping the Engine..............................................  28

H

Hoses and Clamps - Inspect/Replace...................  66

Replace the Hoses and the Clamps .................. 67

I

Important Safety Information ................................... 2

T

L

Table of Contents..................................................... 3

Turbocharger - Inspect (If Equipped)..................... 69

Inspecting........................................................... 70

Removal and Installation.................................... 69

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

M

Maintenance Interval Schedule ............................. 46

Maintenance Section.............................................  33

Model View Illustrations.........................................  13

1103D Engine Model Views...............................  13

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

Mounting and Dismounting.................................... 10

W

Walk-Around Inspection ........................................ 70

Inspect the Engine  for Leaks and for Loose

Connections.....................................................  70

Warranty Information.............................................  72

Warranty Section...................................................  72

Water Pump - Inspect............................................  71

O

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

P

Product Identification Information..........................  16

Product Information Section .................................. 13

Product Lifting........................................................ 19

This document has been printed from SPI². Not for Resale

 

Product and Dealer Information

Note: For product identification plate locations, see the section “Product Identification Information” in the Operation

and Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

Name:

Branch:

Address:

Dealer Contact

Phone Number

Hours

Sales:

Parts:

Service:

This document has been printed from SPI². Not for Resale