MGV15 Perkins 1506 Manual de Operacion PDF
MGV15 Perkins 1506 Manual de Operacion PDF
MGV15 Perkins 1506 Manual de Operacion PDF
January 2015
Operation and
Maintenance
Manual
1506A-E88TA and 1506C-E88TA
Industrial Engines
LG (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
Fire Prevention and Explosion Prevention ... .. 10 Engine Ratings ........................ ....................... 90
Operation Section
Maintenance Section
4 SEBU9070
Foreword
Safety Section
i05942972
Safety Messages
Illustration 1 g01154807
Typical example
Illustration 2 g03732105
Typical example
Attach a “Do Not Operate” warning tag or a similar • Ensure that all protective guards and all covers are
warning tag to the start switch or to the controls secured in place on the engine.
before the engine is serviced or before the engine is
repaired. Attach the warning tags to the engine and to • Never put maintenance fluids into glass
each operator control station. When appropriate, containers. Glass containers can break.
disconnect the starting controls.
• Use all cleaning solutions with care.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being • Report all necessary repairs.
serviced.
Unless other instructions are provided, perform the
maintenance under the following conditions:
SEBU9070 7
Safety Section
General Hazard Information
• For initial start-up of a new engine or for starting an • Wear a hard hat, protective glasses, and other
engine that has been serviced, make provisions to protective equipment, as required.
stop the engine if an overspeed occurs. The
stopping of the engine may be accomplished by • When work is performed around an engine that is
shutting off the fuel supply and/or the air supply to operating, wear protective devices for ears in order
the engine. Ensure that only the fuel supply line is to help prevent damage to hearing.
shut off. Ensure that the fuel return line is open.
• Do not wear loose clothing or jewelry that can snag
• Start the engine from the operators station (cab). on controls or on other parts of the engine.
Never short across the starting motor terminals or
the batteries. This action could bypass the engine • Ensure that all protective guards and all covers are
neutral start system and/or the electrical system secured in place on the engine.
could be damaged.
• Never put maintenance fluids into glass
Engine exhaust contains products of combustion containers. Glass containers can break.
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated • Use all cleaning solutions with care.
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside. • Report all necessary repairs.
Cautiously remove the following parts. To help Unless other instructions are provided, perform
prevent spraying or splashing of pressurized fluids, the maintenance under the following conditions:
hold a rag over the part that is being removed.
8 SEBU9070
Safety Section
General Hazard Information
Asbestos Information
Perkins equipment and replacement parts that are
shipped from Perkins engine company limited are
asbestos free. Perkins recommends the use of only
genuine Perkins replacement parts. Use the following
guidelines when you handle any replacement parts
that contain asbestos or when you handle asbestos
debris.
Illustration 7 g00706404
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
Improperly disposing of waste can threaten the
asbestos fibers. Inhaling this dust can be hazardous environment. Potentially harmful fluids should be
to your health. The components that may contain
disposed of according to local regulations.
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The Always use leakproof containers when you drain
asbestos that is used in these components is usually fluids. Do not pour waste onto the ground, down a
bound in a resin or sealed in some way. Normal drain, or into any source of water.
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there are
several guidelines that should be followed:
10 SEBU9070
Safety Section
Burn Prevention
i05943062 i05945996
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Illustration 8 g00704000
Check that the coolant level after the engine has
stopped and the engine has been allowed to cool. All fuels, most lubricants, and some coolant mixtures
are flammable.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch Flammable fluids that are leaking or spilled onto hot
with a bare hand. Remove the filler cap slowly in surfaces or onto electrical components can cause a
order to relieve pressure. fire. Fire may cause personal injury and property
damage.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact After the emergency stop button is operated, ensure
the skin, the eyes, or the mouth. that you allow 15 minutes, before the engine covers
are removed.
Oils Determine whether the engine will be operated in an
Skin may be irritated following repeated or prolonged environment that allows combustible gases to be
exposure to mineral and synthetic base oils. Refer to drawn into the air inlet system. These gases could
your suppliers Material Safety Data Sheets for cause the engine to overspeed. Personal injury,
detailed information. Hot oil and lubricating property damage, or engine damage could result.
components can cause personal injury. Do not allow
hot oil to contact the skin. Appropriate personal If the application involves the presence of
protective equipment should be used combustible gases, consult your Perkins dealer and/
or your Perkins distributor for additional information
Diesel Fuel about suitable protection devices.
Diesel may be irritating to the eyes, respiratory Remove all flammable combustible materials or
system, and skin. Prolonged exposure to diesel may conductive materials such as fuel, oil, and debris from
the engine. Do not allow any flammable combustible
cause various skin conditions. Appropriate personal materials or conductive materials to accumulate on
protective equipment should be used. Refer to the engine.
supplier Material safety Data sheets for detailed
information. Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
Batteries oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
Electrolyte is an acid. Electrolyte can cause personal storing flammable materials.
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for Do not expose the engine to any flame.
servicing batteries. Wash hands after touching the
batteries and connectors. Use of gloves is Exhaust shields (if equipped) protect hot exhaust
recommended. components from oil or fuel spray in case of a line, a
tube, or a seal failure. Exhaust shields must be
installed correctly.
SEBU9070 11
Safety Section
Fire Prevention and Explosion Prevention
Do not weld on lines or tanks that contain flammable Avoid static electricity risk when fueling. Ultra-low
fluids. Do not flame cut lines or tanks that contain Sulfur Diesel fuel (ULSD fuel) poses a greater static
flammable fluid. Clean any such lines or tanks ignition hazard than earlier diesel formulations with a
thoroughly with a nonflammable solvent prior to higher sulfur content. Avoid death or serious injury
welding or flame cutting. from fire or explosion. Consult your fuel or fuel system
supplier to ensure that the delivery system is in
Wiring must be kept in good condition. Ensure that all compliance with fueling standards for proper
electrical wires are correctly installed and securely grounding and bonding practices.
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.
Ensure that the engine is stopped. Inspect all lines
and hoses for wear or for deterioration. Ensure that
the hoses are correctly routed. The lines and hoses
must have adequate support and secure clamps.
Oil filters and fuel filters must be installed correctly.
The filter housings must be tightened to the correct
torque. Refer to the Disassembly and Assembly
manual for more information.
Illustration 10 g00704135
Ether
Ether is flammable and poisonous.
12 SEBU9070
Safety Section
Crushing Prevention and Cutting Prevention
Do not smoke while you are replacing an ether Chips or other debris may fly off objects when objects
cylinder or while you are using an ether spray. are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49° C i05463929
(120° F). Keep ether cylinders away from open
flames or sparks. Mounting and Dismounting
Lines, Tubes, and Hoses
Do not climb on the engine. The engine has not been
Do not bend high-pressure lines. Do not strike high- designed with mounting or dismounting locations.
pressure lines. Do not install any lines that are
damaged. Refer to the Original Equipment Manufacture (OEM)
for the location of foot and hand holds for your
Leaks can cause fires. Consult your Perkins dealer or specific application.
your Perkins distributor for replacement parts.
Replace the parts if any of the following conditions i04257031
are present:
• End fittings are damaged or leaking.
Before Starting Engine
• Outer coverings are chafed or cut.
• Wires are exposed. NOTICE
For initial start-up of a new or rebuilt engine, and for
• Outer coverings are ballooning. start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
• Flexible parts of the hoses are kinked. occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, Engine exhaust contains products of combustion
correct installation will help to prevent vibration, which may be harmful to your health. Always start
rubbing against other parts, and excessive heat. and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
i02143194 outside.
Engine Electronics
Product Information
Section
General Information
i05946031
Illustration 12 g03733708
Typical example
(1) Engine air cleaner service indicator (4) Radiator pressure cap (7) Air cleaner
(2) Inspection guard (5) Air-to-air aftercooler (8) Vacuator valve (Dust valve)
(3) Radiator (6) Rain cap
16 SEBU9070
General Information
Model View Illustrations
Engine Views
Illustration 13 g03734120
Typical example
(9) Cooling fan (12) Fuel priming pump (15) Belts for fan
(10) Oil filler cap (13) Secondary fuel filter
(11) Starting motor assembly (14) Primary fuel filter
SEBU9070 17
General Information
Model View Illustrations
Illustration 14 g03734121
Typical example
(16) Rear lifting eye (19) Front lifting location (23) coolant pump
(17) Coolant sampling valve (20) Belt for coolant pump (24) Oil filter
(18) Housing for coolant temperature (21) Crankshaft damper (25) Oil gauge (Dipstick)
regulator (22) Idler for coolant belt (26) Sample valve for engine oil
18 SEBU9070
General Information
Model View Illustrations
Illustration 15 g03734133
Typical example
(27) Turbocharger (29) Oil pan (31) Flywheel housing
(28) Alternator (30) Oil drain tap (32) Flywheel
SEBU9070 19
General Information
Product Description
Illustration 16 g03734135
Typical example
(33) Unit injector hydraulic pump (35) Crankcase breather (37) Breather outlet hose
(34) Fuel transfer pump (36) Electronic control module (38) Oil drain plug
Additional Features
The following additional features provide increased
engine fuel economy and serviceability:
• Cold starting capability
• Tampering detection
• Diagnostics
Illustration 19 g01403841
Engine Identification
Perkins engines are identified by an engine serial
number.
A typical example of an engine serial number is
LGE F**** N00001W.
L Type of engine
Illustration 18 g03735788
Typical example G Application (Table 2 )
(1) Location of engine serial plate.
E Rating Type (Table 3 )
Perkins engines are identified by serial numbers.
These numbers are shown on the engine serial F Number of cylinders (Table 4 )
number plate. Perkins distributors need these
numbers in order to determine the components that ***** Fixed build number
were included with the engine. This information N Built in the USA
permits accurate identification of replacement part
numbers. 00001 Engine Number
W Year of Manufacture
Table 2
Application
G Genset
Table 3
Type of engine (Diesel)
A TAG1
B TAG2
D TAG3
(continued)
SEBU9070 23
Product Identification Information
Emissions Certification Film
Table 4
Number of Cylinders
F 6
H 8
M 12
R 16
i05951816
i05951812
Reference Information
Operation Section
Product Lifting
Illustration 21 g00103219
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.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
The lifting eyes (1) are the lifting locations for lifting Some removals require lifting the fixtures in order to
the engine and radiator. obtain proper balance and safety.
Lifting eyes are designed and installed for the specific
engine arrangement. 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 distributor for information regarding fixtures
for proper engine lifting.
i05951855
Product Storage
b. Fill the fuel system with a correct specification 2. Check the condition of the coolant pump belt and
of fuel. For more information on acceptable the fan drive belts before tensioning the belts.
fuels refer to this Operation and Maintenance Tension the coolant pump belts and tension the fan
Manual, “Fluid recommendations”. Operate the drive belts. Refer to this Operation and
engine for 15 minutes in order to remove all Maintenance Manual, “Belts - Inspect/Adjust” for
biodiesel from the system. more information.
2. Drain any water from the primary filter water 3. Check the coolant level. Refer to Operation and
separator. Ensure that the fuel tank is full. Maintenance Manual, “Coolant Level - Check”
3. Change the engine oil and filter. Refer to this 4. Remove valve cover, refer to Disassembly and
Operation and Maintenance Manual, “Engine Oil Assembly, “Valve Mechanism Cover - Remove and
and Filter - Change”. Ensure that the engine is Install”. Lubricate the valve train. Install the valve
operated after the oil and filter has been changed. cover.
Ensure that engine oil pressure is correct before 5. Replace the fuel filters. Refer to the following
stopping the engine. section within the Operation and Maintenance
Manual.
4. For the correct specification of engine oil refer to
this Operation and Maintenance Manual, “Fluid • Fuel System Primary Filter (Water Separator)
recommendations”. Element - Replace
5. Loosen the fan drive belts and loosen the coolant
• Fuel System Secondary Filter - Replace
pump belt. Refer to this Operation and
Maintenance Manual, “Belts - Inspect/Adjust” for • Fuel System - Prime
more information.
6. Use a bar or a turning tool in order to turn the
Sealed Coolant System engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
Ensure that the cooling system is filled with Perkins resistance exist.
ELC, or an antifreeze that meets “ASTM D6210”
specification.
26 SEBU9070
Lifting and Storage
Product Storage
Illustration 22 g03774288
(1) Plug
Engine Oil Pressure – Typical oil Service Hour Meter – This gauge
pressure for an engine at rated speed indicates the total number of clock hours
with SAE 10W30 or with SAE 15W40 is of engine operation. Hours of operation
240 to 480 kPa (35 to 70 psi). are logged in the ECM. A service tool is needed to
retrieve the hours from the ECM. A Service Hour
Engine Oil Temperature – This gauge Meter may be installed on the engine.
indicates the engine oil temperature. An
oil temperature that is higher than Fuel Level – This gauge indicates the
normal indicates a heat problem in the lubrication level of fuel in the fuel tank. The fuel
system and/or the cooling system. This problem level gauge registers the fuel level only
can damage the cylinder heads, the cylinder when the ignition switch is in the ON position.
liners, the pistons, and the crankshaft bearings.
Warning Indicators
Jacket Water Coolant Temperature –
Typical temperature range is 88 to 102 °C There are two warning lamps available.
(190 to 215 °F). The maximum allowable
• Warning Lamp
temperature with the pressurized cooling system
is 105 °C (220 °F). Higher temperatures may • Shutdown Lamp
occur under certain conditions. The water
temperature reading may vary according to load. Instrument Panels and Displays
The reading should never exceed the boiling
point for the pressurized system that is being In order to monitor the engine a wide verity of
used. instrument panels are available. These instrument
panels can contain the indicator lamps and the
If the engine is operating above the normal range or gauges for the application.
steam becomes apparent, perform the following
procedure: Also available are mini power displays and
performance monitors.
1. Reduce the engine load .
i05964915
2. Inspect the cooling system for leaks.
Diagnostic
If there is a fault with an engine protection sensor on
the engine, the engine activates a diagnostic code.
The engine communicates the diagnostic code to the
operator via the Diagnostic output. The diagnostic
code provides an indication to the operator of a fault
with the engine protection system. Running of the
engine for a prolonged period in this condition may
result in engine failure. The output can be used to
drive lamps or relays.
30 SEBU9070
Features and Controls
Sensors and Electrical Components
Illustration 23 g03745560
Typical example
(1) Coolant sensor (6) Injector harness connection (11) Oil pressure sensor
(2) Injection actuation pressure control valve (7) Atmospheric pressure sensor (12) Fuel temperature sensor
(3) Fuel rail pressure sensor (8) Probe for top center position (13) Fuel pressure sensor
(4) Intake air pressure sensor (9) Electronic control module (14) Speed timing sensor
(5) Intake air temperature sensor (10) Starting motor (15) Speed timing sensor
SEBU9070 31
Features and Controls
Sensors and Electrical Components
Illustration 24 g03745561
Typical example
(16) Alternator
32 SEBU9070
Features and Controls
Sensors and Electrical Components
Illustration 25 g03745623
Typical example
(1) Coolant sensor (3) Fuel rail pressure sensor (5) Intake air temperature sensor
(2) Injection actuation pressure control valve (4) Intake air pressure sensor (6) Injector harness connection
SEBU9070 33
Features and Controls
Sensors and Electrical Components
Illustration 26 g03746096
Typical example
(7) Atmospheric pressure sensor (9) Electronic control module (11) Oil pressure sensor
(8) Probe for top center position (10) Starting motor (12) Fuel temperature sensor
34 SEBU9070
Features and Controls
Sensors and Electrical Components
Illustration 27 g03746099
Typical example
(13) Fuel pressure sensor (14) Speed timing sensor (15) Speed timing sensor
Illustration 28 g03746100
Typical example
(16) Alternator
SEBU9070 35
Engine Diagnostics
Self-Diagnostics
i02784187
Engine Operation with Active
Diagnostic Codes
Self-Diagnostics
If a diagnostic lamp illuminates during normal engine
The electronic control module has some self- operation, the system has identified a situation that is
diagnostic ability. When an electronic problem with an not within the specification. Use the electronic service
input or an output is detected, a diagnostic code is tool to check the active diagnostic codes.
generated. This indicates the specific problem with
the circuitry. The active diagnostic code should be investigated.
The cause of the problem should be corrected as
A diagnostic code which represents a problem that soon as possible. If the cause of the active diagnostic
currently exists is called an active code. code is repaired and there is only one active
diagnostic code, the diagnostic lamp will turn off.
A diagnostic code that is stored in memory is called a
logged code. Always service active codes prior to Operation of the engine and performance of the
servicing logged codes. Logged codes may indicate engine can be limited as a result of the active
intermittent problems. diagnostic code that is generated. Acceleration rates
may be significantly slower and power outputs may
Logged codes may not indicate that a repair is be automatically reduced. Refer to Troubleshooting,
needed. The problems may have been repaired since “Troubleshooting with a Diagnostic Code” for more
the logging of the code. Logged codes may be helpful information on the relationship between each active
to troubleshoot intermittent problems. diagnostic code and the possible effect on engine
performance.
i02572812
i02784585
Diagnostic Lamp
Engine Operation with
Intermittent Diagnostic Codes
The “DIAGNOSTIC” lamp is used to indicate the
existence of an active fault.
A fault diagnostic code will remain active until the If a diagnostic lamp illuminates during normal engine
problem is repaired. operation and the diagnostic lamp shuts OFF, an
intermittent fault may have occurred. If a fault has
occurred, the fault will be logged into the memory of
i02784192
the Electronic Control Module (ECM).
Fault Logging In most cases, it is not necessary to stop the engine
because of an intermittent code. However, the
operator should retrieve the logged fault codes and
the operator should reference the appropriate
The system provides the capability of Fault Logging. information in order to identify the nature of the fault.
When the Electronic Control Module (ECM) The operator should log any observation that could
generates an active diagnostic code, the code will be have caused the lamp to light.
logged in the memory of the ECM. The Perkins
electronic service tool can retrieve codes that have • Low power
been logged. The codes that have been logged can
be cleared with the Perkins electronic service tool. • Limits of the engine speed
The codes that have been logged in the memory of
the ECM will be automatically cleared from the • Excessive smoke, etc
memory after 100 hours.
This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting guide for this
engine.
36 SEBU9070
Engine Diagnostics
Configuration Parameters
i05985293
Configuration Parameters
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
i05953831 to the controls.
Before Starting Engine • Ensure that the areas around the rotating parts are
clear.
• For the maximum service life of the engine, make • Disconnect any battery chargers that are not
a thorough inspection before starting the engine. protected against the high current drain that is
Look for the following items: oil leaks, coolant created when the electric starting motor (if
leaks, loose bolts and trash buildup. Remove trash equipped) is engaged. Check electrical cables and
buildup and arrange for repairs, as needed. check the battery for poor connections and for
corrosion.
• Inspect the cooling system hoses for cracks and
for loose clamps. • Reset any of the shutoff components or alarm
components.
• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage. • Check the engine lubrication oil level. Maintain the
oil level between the “ADD” mark and the “FULL”
• Inspect the wiring for loose connections and for mark on the oil level gauge.
worn wires or frayed wires.
• Check the coolant level, maintain the coolant level
• Check the fuel supply. Drain water from the water within 13 mm (0.5 inch) from the neck of the
separator (if equipped). Open the fuel supply radiator cap.
valve.
• Observe the air cleaner service indicator. Service
NOTICE the air cleaner when the yellow diaphragm enters
All valves in the fuel return line must be open before the red zone, or when the red piston locks in the
and during engine operation to help prevent high fuel visible position.
pressure. High fuel pressure may cause filter housing
failure or other damage. i05972399
If the engine has not been run for several weeks, fuel
Cold Weather Starting
may have drained from the fuel system. Air may have
entered the filter housing. Also, when fuel filters have
been changed, some air space will be left in the
housing. In these instances, prime the fuel system.
Refer to the Operation and Maintenance Manual,
“Fuel System - Prime” for more information on priming Do not use aerosol types of starting aids such as
the fuel system. ether. Such use could result in an explosion and
personal injury.
If the engine has not been run for several weeks, fuel
NOTICE may have drained. Air may have moved into the filter
Do not engage the starting motor when flywheel is housing. Also, when fuel filters have been changed,
turning. Do not start the engine under load. some air will be left in the filter housing. Refer to
Operation and Maintenance Manual, “Fuel System -
If the engine fails to start within 30 seconds, release Prime” in order to remove air from the fuel system.
the starter switch or button and wait 30 seconds to al-
low the starting motor to cool before attempting to Use the procedure that follows for cold weather
start the engine again. starting.
Note: Check all gauges and indicators for correct 3. If the engine fails to start, investigate the problem.
operation. A system fault may be indicated after the Use the Perkins electronic service tool. A system
engine is started. If this indication occurs, the ECM fault may be indicated after the engine is started. If
has detected a problem with the system. The fault this occurs the ECM has detected a problem with
must be investigated. the system. Investigate the cause of the problem.
5. Oil pressure should rise within 15 seconds after the Use the Perkins electronic service tool.
engine starts. The engine electronic controls
monitor the engine oil pressure. The electronic Note: Oil pressure should rise within 15 seconds after
controls will stop the engine if the oil pressure is the engine starts. The electronic engine controls
below normal. monitor the oil pressure. The electronic controls will
stop the engine if the oil pressure is below normal.
i02815193 4. Operate the engine at no load until all the coolant
temperature starts to rise. Check the gauges
Cold Weather Starting during the warm-up period.
i05975875
NOTICE
Using a battery source with the same voltage as the
Starting the Engine electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
1. Disengage any equipment that is driven by the Do not reverse the battery cables. The alternator can
engine. be damaged. Attach ground cable last and remove
first.
2. Turn keyswitch to the ON position and check for
correct operation of gauges and indicators. Refer Turn all electrical accessories OFF before attaching
to original equipment manufacturer for information the jump start cables.
on the starting control panel. Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
gine being started.
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load. 1. Turn the start switch on the stalled engine to the
OFF position. Turn off all the engines accessories.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to al- 2. Connect one positive end of the jump-start cable to
low the starting motor to cool before attempting to
start the engine again. 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
3. Turn keyswitch in order to crank engine and when electrical source.
engine fires release keyswitch.
3. Connect one negative end of the jump-start cable
4. If the engine fails to start, repeat step 2 to 3 repeat to the negative cable terminal of the electrical
these steps three times only. source. Connect the other negative end of the
jump-start cable to the engine block or to the
5. If the engine fails to start, refer to Troubleshooting, chassis ground. This procedure helps to prevent
“Engine Cranks but Does Not Start”. potential sparks from igniting the combustible
gases that are produced by some batteries.
i05954108
Starting with Jump Start Note: The engine ECM must be powered before the
starting motor is operated or damage can occur.
Cables 4. Start the engine in the normal operating procedure.
Refer to this Operation and Maintenance Manual,
“Starting the Engine”.
i05954148
Ensure that the self test for the monitoring system (if
equipped) is completed before operating the engine
under load.
The engine will operate at a content speed. The
speed will be programmed in to the electronic control
unit. Check all gauges and indicator lamps after
starting for correct reading and correct actions.
Visually check for coolant, oil, or fuel leaks.
Allow the engine 3 minutes warm up time before
applying load.
Engine Operation Shut off the engine instead of operating the engine at
no load for long periods of time.
• Observe the service indicator for the air cleaner
Proper operation and maintenance are key factors in frequently. Keep the air cleaner elements clean.
obtaining the maximum life and economy of the
engine. If the directions in the Operation and • Maintain a good electrical system.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. One bad battery cell will overwork the alternator and
will consume excess power and excess fuel.
The time that is needed for the engine to reach
normal operating temperature can be less than the • Ensure that the belts are properly adjusted. The
time needed for a walk-around inspection of the belts should be in good condition.
engine.
• Ensure that all of the connections of the hoses are
After the engine is started and after the engine tight. The connections should not leak.
reaches normal operating temperature, the engine
can be operated at load. • Ensure that the driven equipment is in good
Gauge readings should be observed and the data working order.
should be recorded frequently while the engine is
operating. Comparing the data over time will help to • Cold engines consume excess fuel. Keep cooling
determine normal readings for each gauge. system components clean and keep cooling
Comparing data over time will also help detect system components in good repair. Never operate
abnormal operating developments. Significant the engine without water temperature regulators.
changes in the readings should be investigated. All of these items will help maintain operating
temperatures.
i05954310
i05954305
Cold Weather Operation The cloud point of the fuel is the temperature at which
waxes naturally found in the diesel fuel begin to form
crystals. The cloud point of the fuel must be below
i05954317 lowest ambient temperature to prevent filters from
plugging.
Radiator Restrictions Cold Filter Plugging Point is a temperature at which a
particular fuel will pass through a standardized
filtration device. This CFPP gives an estimate of the
Perkins discourages the use of airflow restriction lower operability temperature of fuel
devices that are mounted in front of radiators. Airflow
restriction can cause the following conditions: Pour point is the last temperature before the fuel flow
stops and waxing of the fuel will start.
• High exhaust temperatures
Be aware of these properties when diesel fuel is
• Power loss purchased. Consider the average ambient air
temperature for the engines application. Engines that
• Excessive fan usage are fueled in one climate may not operate well if the
engines are shipped to colder climate. Problems can
• Reduction in fuel economy result due to changes in temperature.
If an airflow restriction device must be used, the Before troubleshooting for low power or for poor
device should have a permanent opening directly in performance in the winter, check the fuel for waxing
line with the fan hub. The device must have a
minimum opening dimension of at least 770 cm2 The following components can provide a means of
(120 in2). minimizing fuel waxing problems in cold weather:
A centered opening that is directly in line with the fan • Fuel heaters, which may be an OEM option
hub is specified in order to prevent an interrupted
airflow on the fan blades. Interrupted airflow on the • Fuel line insulation, which may be an OEM option
fan blades could cause a fan failure.
Winter and arctic grades of diesel fuel are available in
Perkins recommends a warning device for the inlet the countries and territories with severe winters. For
manifold temperature and/or the installation of an inlet more information refer to the Operation and
air temperature gauge. The warning device for the Maintenance Manual, “Fuel For Cold Weather
inlet manifold temperature should be set at 75 °C Operation”
(167 °F). The inlet manifold air temperature should
not exceed 75 °C (167 °F). Temperatures that Another important fuel property which can affect cold
exceed this limit can cause power loss and potential start and operation of diesel engine is Cetane
engine damage. number. Detail and requirements of this property are
given in this Operation and Maintenance Manual,
i05954321
“Fluid Recommendations”.
• Weekly
• Oil changes
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater with
a large heating surface. The fuel heater should be
practical in size. Small heaters can be too hot due to
the limited surface area.
Disconnect the fuel heater in warm weather.
i05955161
After Stopping Engine
Emergency Stopping 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.
NOTICE
• Check the crankcase oil level. Maintain the oil level
Emergency shutoff controls are for EMERGENCY
between the “LOW” mark and the “HIGH” mark
use ONLY. DO NOT use emergency shutoff devices
on the oil level gauge.
or controls for normal stopping procedure.
Note: Only use oil that is recommended in this
The OEM may have equipped the application with an Operation and Maintenance Manual, “Fluid
emergency stop button. For more information about Recommendations”. Failure to use the recommended
the emergency stop button, refer to the OEM oil may result in engine damage.
information.
• If necessary, perform minor adjustments. Repair
Ensure that any components for the external system any leaks and tighten any loose bolts.
that support the engine operation are secured after
the engine is stopped. • Note the service hour meter reading. Perform the
maintenance that is in the Operation and
i05955160
Maintenance Manual, “Maintenance Interval
Schedule”.
Manual Stop Procedure • Fill the fuel tank in order to help prevent
accumulation of moisture in the fuel. Do not overfill
the fuel tank.
Stopping the Engine • Allow the engine to cool. Check the coolant level.
Maintain the cooling system at 13 mm (0.5 inch)
NOTICE from the bottom of the pipe for filling.
Stopping the engine immediately after it has been
working under load, can result in overheating and ac- Note: Only use coolant that is recommended in this
celerated wear of the engine components. Operation and Maintenance Manual, “Fluid
Recommendations”. Failure to use the recommended
Avoid accelerating the engine prior to shutting it oil may result in engine damage.
down.
• If freezing temperatures are expected, check the
Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life. coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
Note: Individual applications will have different the proper coolant/water mixture, if necessary.
control systems. Ensure that the shutoff procedures
are understood. Use the following general guidelines • Perform all required periodic maintenance on all
in order to stop the engine. driven equipment. This maintenance is outlined in
the instructions from the OEM.
1. Remove the load from the engine. Allow the engine
to run under no load conditions for 5 minutes in
order to cool the engine.
Fluid Recommendations
Refill Capacities
i05955174 General Coolant Information
Refill Capacities NOTICE
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first.
Lubrication System
NOTICE
The refill capacities for the engine crankcase reflect If the engine is to be stored in, or shipped to an area
the approximate capacity of the crankcase or sump with below freezing temperatures, the cooling system
plus standard oil filters. Auxiliary oil filter systems will must be either protected to the lowest outside temper-
require additional oil. Refer to the OEM specifications ature or drained completely to prevent damage.
for the capacity of the auxiliary oil filter. Refer to the
Operation and Maintenance Manual, “Maintenance
Section” for more information on Lubricant
Specifications. NOTICE
Table 5 Frequently check the specific gravity of the coolant for
proper freeze protection or for anti-boil protection.
Engine
Refill Capacities
Clean the cooling system for the following reasons:
Compartment or At Commissioning In Service
System
• Contamination of the cooling system
Crankcase Oil Sump 41 L 39 L
(1) • Overheating of the engine
(1) These values are the approximate capacities for the crankcase • Foaming of the coolant
oil sump (aluminum) which includes the standard factory in-
stalled oil filters. Engines with auxiliary oil filters will require addi-
tional oil. Refer to the OEM specifications for the capacity of the NOTICE
auxiliary oil filter. Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
Cooling System proper operating temperature. Cooling system prob-
Refer to the OEM specifications for the External lems can develop without water temperature
System capacity. This capacity information will be regulators.
needed in order to determine the amount of coolant
that is required for the Total Cooling System.
Many engine failures are related to the cooling
Table 6 system. The following problems are related to cooling
Engine system failures: Overheating, leakage of the water
Refill Capacities pump and plugged radiators or heat exchangers.
Compartment or System Liters These failures can be avoided with correct cooling
system maintenance. Cooling system maintenance is
Engine Only 14 as important as maintenance of the fuel system and
External System Per OEM(1)
the lubrication system. Quality of the coolant is as
33
important as the quality of the fuel and the lubricating
(1) The External System includes a radiator or an expansion tank oil.
with the following components: heat exchanger and piping. Re-
fer to the OEM specifications. Enter the value for the capacity of Coolant is normally composed of three elements:
the External System in this row. Water, additives and glycol.
Water
Water is used in the cooling system in order to
transfer heat.
46 SEBU9070
Refill Capacities
Fluid Recommendations
Preferred – Perkins ELC 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
Acceptable – A commercial heavy-duty antifreeze contains organic corrosion inhibitors and antifoam
that meets “ASTM D6210” specifications agents with low amounts of nitrite. Perkins ELC has
been formulated with the correct amount of these
additives in order to provide superior corrosion
NOTICE protection for all metals in engine cooling systems.
The 1200 series industrial engines must be oper-
ated with a 1:1 mixture of water and glycol. This ELC is available in a premixed cooling solution with
concentration allows the NOx reduction system to distilled water. ELC is a 1:1 mixture. The Premixed
operate correctly at high ambient temperatures. 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.
NOTICE
Do not use a commercial coolant/antifreeze that only Containers of several sizes are available. Consult
meets the ASTM D3306 specification. This type of your Perkins distributor for the part numbers.
coolant/antifreeze is made for light automotive
applications. ELC Cooling System Maintenance
Correct additions to the Extended Life
Perkins recommends a 1:1 mixture of water and
glycol. This mixture of water and glycol will provide Coolant
optimum heavy-duty performance as an antifreeze.
This ratio may be increased to 1:2 water to glycol if
extra freezing protection is required. NOTICE
Use only Perkins products for pre-mixed or concen-
A mixture of SCA inhibitor and water is acceptable trated coolants.
but will not give the same level of corrosion, boiling
and, freezing protection as ELC. Perkins Mixing Extended Life Coolant with other products re-
recommends a 6 percent to 8 percent concentration duces the Extended Life Coolant service life. Failure
of SCA in those cooling systems. Distilled water or to follow the recommendations can reduce cooling
deionized water is preferred. Water which has the system components life unless appropriate corrective
recommended properties may be used. action is performed.
Table 10
Coolant Service Life In order to maintain the correct balance between the
antifreeze and the additives, you must maintain the
Coolant Type Service Life (1) recommended concentration of ELC. Lowering the
proportion of antifreeze lowers the proportion of
6,000 Service Hours or Three
Perkins ELC additive. This lowering will lower the ability of the
Years
coolant to protect the system from pitting, from
Commercial Heavy-Duty Anti- cavitation, from erosion, and from deposits.
freeze that meets “ASTM 3000 Service Hours or Two Year
D6210” NOTICE
Commercial SCA inhibitor and Do not use a conventional coolant to top-off a cooling
3000 Service Hours or One Year system that is filled with Extended Life Coolant (ELC).
Water
(1) Use the interval that occurs first. The cooling system must also Do not use standard supplemental coolant additive
be flushed out at this time.
(SCA).
Clean water is the only cleaning agent that is required Note: The cooling system cleaner must be thoroughly
when ELC is drained from the cooling system. flushed from the cooling system. Cooling system
cleaner that is left in the system will contaminate the
Before the cooling system is filled, the heater control coolant. The cleaner may also corrode the cooling
(if equipped) must be set to the HOT position. Refer system.
to the OEM in order to set the heater control. After the
cooling system is drained and the cooling system is 8. Repeat Steps 6 and repeat steps 7 until the system
refilled, operate the engine until the coolant level is completely clean.
reaches the normal operating temperature and until
the coolant level stabilizes. As needed, add the 9. Fill the cooling system with the Perkins Premixed
coolant mixture in order to fill the system to the ELC.
specified level.
ELC Cooling System Contamination
Changing to Perkins ELC
To change from heavy-duty antifreeze to the Perkins NOTICE
ELC, perform the following steps: Mixing ELC with other products reduces the effective-
ness of the ELC and shortens the ELC service life.
NOTICE Use only Perkins Products for premixed or concen-
Care must be taken to ensure that all fluids are con- trate coolants. Failure to follow these recommenda-
tained during performance of inspection, mainte- tions can result in shortened cooling system
nance, testing, adjusting and the repair of the component life.
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or disas-
ELC cooling systems can withstand contamination to
sembling any component containing fluids. a maximum of 10 percent of conventional heavy-duty
Dispose of all fluids according to local regulations and antifreeze or SCA. If the contamination exceeds 10
percent of the total system capacity, perform ONE of
mandates. the following procedures:
1. Drain the coolant into a suitable container. • Drain the cooling system into a suitable container.
Dispose of the coolant according to local
2. Dispose of the coolant according to local regulations. Flush the system with clean water. Fill
regulations. the system with the Perkins ELC.
3. Flush the system with clean water in order to • Drain a portion of the cooling system into a
remove any debris. suitable container according to local regulations.
Then, fill the cooling system with premixed ELC.
4. Use an appropriate cleaner to clean the system. This procedure should lower the contamination to
Follow the instruction on the label. less than 10 percent.
5. Drain the cleaner into a suitable container. Flush • Maintain the system as a conventional Heavy-Duty
the cooling system with clean water. Coolant. Treat the system with an SCA. Change
the coolant at the interval that is recommended for
6. Fill the cooling system with clean water and the conventional Heavy-Duty Coolant.
operate the engine until the engine is warmed to
49° to 66°C (120° to 150°F). Commercial Heavy-Duty Antifreeze and
SCA
NOTICE
Incorrect or incomplete flushing of the cooling system NOTICE
can result in damage to copper and other metal Commercial Heavy-Duty Coolant which contains
components. Amine as part of the corrosion 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.
(1) When using fuel with 0.10% sulfur (1000 ppm) or higher, refer to
this Operation and Maintenance Manual, “Severe Service Appli-
cation” for more information.
(2) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
Illustration 29 g03739817
refer to TBN and engine oil guidelines given in this section.
Typical API symbol
Table 15
Classifications for the 1506 Industrial Engine
Oil Specification
CH-4
SEBU9070 51
Refill Capacities
Fluid Recommendations
General Information
NOTICE
Every attempt is made to provide accurate, up-to-date
information. By use of this document you agree that
Perkins Engines Company Limited is not responsible
for errors or omissions.
SEBU9070 53
Refill Capacities
Fluid Recommendations
Table 17
Perkins Specification for Distillate Diesel Fuel
Cloud Point °C The cloud point must not ex- D2500 “ISO 3015”
ceed the lowest expected
ambient temperature.
Gums and Resins(5) mg/100mL 10 mg per 100 mL maximum D381 “ISO 6246”
(continued)
54 SEBU9070
Refill Capacities
Fluid Recommendations
Viscosity
NOTICE
Operating with fuels that do not meet the Perkins rec- Viscosity is the property of a liquid of offering
ommendations can cause the following effects: Start- resistance to shear or flow. Viscosity decreases with
ing difficulty, poor combustion, deposits in the fuel increasing temperature. This decrease in viscosity
injectors, reduced service life of the fuel system, de- follows a logarithmic relationship for normal fossil
posits in the combustion chamber and reduced serv- fuel. The common reference is to kinematic viscosity.
ice life of the engine. Kinematic viscosity is the quotient of the dynamic
viscosity that is divided by the density. The
Engines that are manufactured by Perkins are certi- determination of kinematic viscosity is normally by
fied with the fuel that is prescribed by the United readings from gravity flow viscometers at standard
States Environmental Protection Agency. Engines temperatures. Refer to “ISO 3104” for the test
that are manufactured by Perkins are certified with method.
the fuel that is prescribed by the European Certifica-
tion and other regulatory agencies. Perkins does not The viscosity of the fuel is significant because fuel
certify diesel engines on any other fuel. serves as a lubricant for the fuel system components.
Fuel must have sufficient viscosity in order to
lubricate the fuel system in both cold temperatures
Note: The owner and the operator of the engine has and hot temperatures. If the kinematic viscosity of the
the responsibility of using the fuel that is prescribed fuel is lower than 1.4 cSt at the fuel injection pump,
by the Environmental Protection Agency (EPA) and damage to the fuel injection pump can occur. This
other appropriate regulatory agencies. damage can be excessive scuffing and seizure. Low
viscosity may lead to difficult hot restarting, stalling,
Diesel Fuel Characteristics and loss of performance. High viscosity may result in
seizure of the pump.
Perkins Recommendations
Perkins recommends kinematic viscosities of 1.4 and
4.5 cSt that is delivered to the fuel injection pump. If a
Cetane Number fuel with a low viscosity is used, cooling of the fuel
may be required to maintain 1.4 cSt or greater
Fuel that has a high cetane number will give a shorter viscosity at the fuel injection pump. Fuels with a high
ignition delay. A high cetane number will produce a viscosity might require fuel heaters in order to lower
better ignition quality. Cetane numbers are derived for the viscosity to 4.5 cSt at the fuel injection pump.
fuels against proportions of cetane and
heptamethylnonane in the standard CFR engine.
Refer to “ISO 5165” for the test method. Density
Cetane numbers in excess of 45 are normally Density is the mass of the fuel per unit volume at a
expected from current diesel fuel. However, a cetane specific temperature. This parameter has a direct
number of 40 may be experienced in some territories. influence on engine performance and a direct
The United States of America is one of the territories influence on emissions. This influence determines the
that can have a low cetane value. A minimum cetane heat output from a given injected volume of fuel. This
value of 40 is required during average starting parameter is quoted in the following kg/m3 at 15 °C
conditions. A higher cetane value may be required for (59 °F).
operations at high altitudes or in cold-weather
operations. Perkins recommends a value of density of 841 kg/m3
in order to obtain the correct power output. Lighter
Fuel with a low cetane number can be the root cause fuels are acceptable but these fuels will not produce
of problems during cold start. the rated power.
SEBU9070 55
Refill Capacities
Fluid Recommendations
Sulfur NOTICE
The level of sulfur is governed by emissions The fuels system has been qualified with fuel having
legislations. Regional regulation, national regulations, lubricity up to 0.46 mm (0.01811 inch) wear scar di-
or international regulations can require a fuel with a ameter as tested by “ISO 12156-1”. Fuel with higher
specific sulfur limit. The sulfur content of the fuel and wear scar diameter than 0.46 mm (0.01811 inch) will
the fuel quality must comply with all existing local lead to reduced service life and premature failure of
regulations for emissions. the fuel system.
LSD fuel 0.05 percent (≤ 15 ppm (mg/kg)) sulfur is
strongly recommended for use in these engine In case of the fuels which do not meet specified
models. lubricity requirement appropriate lubricity additive can
be used to enhance the lubricity of the fuel. UMK8276
ULSD and sulphur fuel diesel fuels are acceptable to Perkins Diesel Fuel Conditioner is the approved
use in all engine models. The lubricity of these fuels additive refer to “Perkins Diesel Fuel Conditioner”.
must not exceed wear scar diameter of 0.46 mm
(0.01811 inch) as per “ISO 12156-1”. Refer to Contact your fuel supplier for those circumstances
“Lubricity” for more information. Fuels with sulphur when fuel additives are required. Your fuel supplier
content higher than 0.05 percent (500 PPM) can be can make recommendations for additives to use and
used where allowed by legislation. for the proper level of treatment.
In some parts of the world and for some applications,
high sulfur fuels above 0.5% by mass might only be Distillation
available. Fuel with a high sulfur content can cause
engine wear. High sulfur fuel will have a negative Distillation will give an indication of the mixture of
impact on emissions of particulates. High sulfur fuel different hydrocarbons in the fuel. A high ratio of light
can be used if the local emissions legislation will weight hydrocarbons can affect the characteristics of
allow the use. High sulfur fuel can be used in combustion.
countries that do not regulate emissions.
Classification of the Fuels
When only high sulfur fuels are available, it will be
necessary that high alkaline lubricating oil is used in Diesel engines have an ability to burn wide variety of
the engine or that the lubricating oil change interval is fuels. Below is a list of typically encountered fuel
reduced. Refer to Operation and Maintenance specifications that have been assessed as to their
Manual, “Fluid Recommendations (Lubricant acceptability and are divided into following
Information)” for information on sulfur in fuel. categories:
Group 1: Preferred Fuels
Lubricity
The following fuel specifications are considered
Lubricity is the capability of the fuel to prevent pump acceptable.
wear. The lubricity of the fluid describes the ability of
the fluid to reduce the friction between surfaces that Fuels that meet the requirements that are listed in the
are under load. This ability reduces the damage that table 17 .
is caused by friction. Fuel injection systems rely on
the lubricating properties of the fuel. Until fuel sulfur “EN590 - Grades A to F and class 0 to 4”
limits were mandated, the lubricity of the fuel was
believed to be a function of fuel viscosity. “ASTM D975 Grade No. 1-D and 2-D”
The lubricity has particular significance to the current “JIS K2204 Grades 1, 2 & 3 & Special Grade 3”
low viscosity fuel, low sulfur fuel, and low aromatic acceptable provided lubricity ware scar diameter
fossil fuel. These fuels are made in order to meet does not exceed of 0.46 mm (0.01811 inch) as per
stringent exhaust emissions. “ISO 12156-1” .
The lubricity of these fuels must not exceed wear scar “BS2869 - Class A2 Off Highway Gas Oil, Red
diameter of 0.46 mm (0.01811 inch). The fuel lubricity Diesel”
test must be performed on an HFRR, operated at
60 °C (140 °F). Refer to “ISO 12156-1”. Note: The lubricity of these fuels must not exceed
wear scar diameter of 0.46 mm (0.01811 inch) as per
“ISO 12156-1” . Refer to “Lubricity”.
Group 2: Aviation Kerosene Fuels
Following kerosene and jet fuel specifications are
acceptable alternative fuels, and may be used on a
contingency base for emergency or continuous use,
where standard diesel fuel is not available and where
legislation allows their use:
56 SEBU9070
Refill Capacities
Fluid Recommendations
“MIL-DTL-83133 NATO F34 (JP-8)” Raw pressed vegetable oils are NOT acceptable for
use as a fuel in any concentration in compression
“MIL-DTL-83133 NATO F35” engines. Without esterification, these oils may gel in
the crankcase and the fuel tank. These fuels may not
“MIL-DTL-5624 NATO F44 (JP-5)” be compatible with many of the elastomers that are
used in engines that are manufactured today. In
“MIL-DTL-38219 (USAF) (JP7)”
original forms, these oils are not suitable for use as a
“NATO XF63” fuel in compression engines. Alternate base stocks
for biodiesel may include animal tallow, waste
“ASTM D1655 JET A” cooking oils, or various other feedstocks. In order to
use any of the products that are listed as fuel, the oil
“ASTM D1655 JET A1” must be esterified.
Note: Minimum cetane number of 40 is Note: The percentages given are volume-based. The
recommended otherwise cold starting problems or U.S. distillate diesel fuel specification “ASTM D975-
light load misfire might occur. Since jet fuel 09a” includes up to B5 (5 percent) biodiesel.
specifications do not mention cetane requirements,
European distillate diesel fuel specification
Perkins recommends that a fuel sample is taken to “EN590:2010” includes up B7 (7 percent) biodiesel.
determine the cetane number.
Note: Engines that are manufactured by Perkins are
Note: Fuels must have minimum viscosity of 1.4 cSt certified by use of the prescribed Environmental
delivered to the fuel injection pump. Cooling of the Protection Agency (EPA) and European Certification
fuel may be required to maintain 1.4 cSt or greater fuels. Perkins does not certify engines on any other
viscosity at the fuel injection pump. Perkins fuel. The user of the engine has the responsibility of
recommends that the actual viscosity of the fuel, be using the correct fuel that is recommended by the
measured in order to determine if a fuel cooler is manufacturer and allowed by the EPA and other
needed. Refer to “Viscosity”. appropriate regulatory agencies.
Note: Rated power loss of up to 10 percent is
possible due to lower density and lower viscosity of Specification Requirements
jet fuels compared to diesel fuels.
The neat biodiesel must conform to “EN14214” or
“ASTM D6751” (in the USA) and can only be blended
Biodiesel Fuel in mixture of up to 20 percent, by volume in
acceptable mineral diesel fuel meeting requirements
Biodiesel is a fuel that can be defined as mono-alkyl that are listed in table 17 or the latest edition of
esters of fatty acids. Biodiesel is a fuel that can be “EN590” and “ASTM D 975” commercial standards.
made from various feedstock. The most commonly This blend is commonly known as B20.
available biodiesel in Europe is Rape Methyl Ester
(REM). This biodiesel is derived from rapeseed oil. Biodiesel blends are denoted as “BXX” with “XX”
Soy Methyl Ester (SME) is the most common representing the content of neat biodiesel contained
biodiesel in the United States. This biodiesel is in the blend with mineral diesel fuel (for example B5,
derived from soybean oil. Soybean oil or rapeseed oil B10, B20).
are the primary feedstocks. These fuels are together
known as Fatty Acid Methyl Esters (FAME). In United States Biodiesel blends of B6 to B20 must
meet the requirements listed in the latest edition of
“ASTM D7467” (B6 to B20) and must be of an API
gravity of 30-45.
In North America biodiesel and biodiesel blends must
be purchased from the BQ-9000 accredited
producers and BQ-9000 certified distributors.
SEBU9070 57
Refill Capacities
Fluid Recommendations
In other areas of the world, the use of biodiesel that is Perkins T400012 Fuel Cleaner is most effective in
BQ-9000 accredited and certified, or that is cleaning and preventing the formation of deposits.
accredited and certified by a comparable biodiesel Refer to “Perkins Diesel Fuel System Cleaner” for
quality body to meet similar biodiesel quality more information. Perkins UMK8276 Perkins Diesel
standards is required. Fuel Conditioner helps to limit deposit issues by
improving the stability of biodiesel while also
Engine Service Requirements with B20 hindering the production of new deposits. For more
information refer to “Perkins Diesel Fuel
Conditioner”. Therefore the use of Diesel Fuel
Aggressive properties of biodiesel fuel may cause Cleaner and or Diesel Fuel Conditioner is strongly
debris in the fuel tank and fuel lines. The aggressive recommended when running biodiesel blends,
properties of biodiesel will clean the fuel tank and fuel especially B20.
lines. This cleaning of the fuel system can
prematurely block of the fuel filters. Perkins
recommends that after the initial usage of B20 General Requirements
biodiesel blended fuel the fuel filters must be replaced
at 50 hours. Biodiesel has poor oxidation stability, which can result
in long-term problems in the storage of biodiesel.
Glycerides present in biodiesel fuel will also cause Biodiesel fuel should be used within 6 months of
fuel filters to become blocked more quickly. Therefore manufacture. Equipment should not be stored with
the regular service interval should be reduced to 250 the B20 biodiesel blends in the fuel system for longer
hours. than 3 months.
When biodiesel fuel is used, crank case oil and Due to poor oxidation stability and other potential
aftertreatment systems may be influenced. This issues, Perkins strongly recommends that engines
influence is due to the chemical composition and with limited operational time either not use B20
characteristics of biodiesel fuel, such as density and biodiesel blends or, while accepting some risk, limit
volatility, and to chemical contaminants that can be biodiesel blend to a maximum of B5. Examples of
present in this fuel, such as alkali and alkaline metals applications that should limit the use of biodiesel are
(sodium, potassium, calcium, and magnesium). the following: Standby generator sets and certain
emergency vehicles.
• Crankcase oil fuel dilution can be higher when
biodiesel or biodiesel blends are used. This Perkins strongly recommends that seasonally
increased level of fuel dilution when using operated engines have the fuel systems, including
biodiesel or biodiesel blends is related to the fuel tanks, flashed with conventional diesel fuel
before prolonged shutdown periods. An example of
typically lower volatility of biodiesel. In cylinder an application that should seasonally flush the fuel
emissions control strategies utilized in many of the system is a combine harvester.
industrial latest engine designs may lead to a
higher level of biodiesel concentration in the Microbial contamination and growth can cause
engine oil pan. The long-term effect of biodiesel corrosion in the fuel system and premature plugging
concentration in crankcase oil is currently of the fuel filter. Consult your supplier of fuel for
unknown. assistance in selecting appropriate antimicrobial
additive.
• Perkins recommends the use of oil analysis in
order to check the quality of the engine oil if Water accelerates microbial contamination and
growth. When biodiesel is compared to distillate fuels,
biodiesel fuel is used. Ensure that the level of water is naturally more likely to exist in the biodiesel.
biodiesel in the fuel is noted when the oil sample is It is therefore essential to check frequently and if
taken. necessary, drain the water separator.
Performance Related Issues with B20 Materials such as brass, bronze, copper, led, tin, and
zinc accelerate the oxidation process of the biodiesel
Due to the lower energy content than the standard fuel. The oxidation process can cause deposits
distillate fuel B20 will cause a power loss in order of 2 formation therefore these materials must not be used
to 4 percent. In addition, over time the power may for fuel tanks and fuel lines.
deteriorate further due to deposits in the fuel injectors.
Fuel for Cold Weather Operation
Biodiesel and biodiesel blends are known to cause an
increase in fuel system deposits, most significant of The European standard “EN590” contains climate
which are deposits within the fuel injector. These dependant requirements and a range of options. The
deposits can cause a loss in power due to restricted options can be applied differently in each country.
or modified fuel injection or cause other functional There are five classes that are given to arctic climates
issues associated with these deposits. and severe winter climates. 0, 1, 2, 3 and 4.
58 SEBU9070
Refill Capacities
Fluid Recommendations
Fuel that complies with “EN590” CLASS 4 can be Perkins recognizes the fact that additives may be
used at temperatures as low as −44 °C (−47.2 °F). required in some special circumstances. Fuel
Refer to “EN590” for a detailed discretion of the additives need to be used with caution. Contact your
physical properties of the fuel. fuel supplier for those circumstances when fuel
additives are required. Your fuel supplier can
The diesel fuel “ASTM D975 1-D” that is used in the recommend the appropriate fuel additive and the
United States of America may be used in cold correct level of treatment.
temperatures that are below −18 °C (−0.4 °F).
Note: For the best results, your fuel supplier should
In extreme cold ambient conditions, you may use the treat the fuel when additives are required. The treated
aviation kerosene fuels that are specified in
“Classification of the Fuels”. These fuels are intended fuel must meet the requirements that are stated in
to be used in temperatures that can be as low as table 17 .
−54 °C (−65.2 °F). Refer to “Classification of the
Fuels” for detail and conditions of use of the aviation Perkins Diesel Fuel System Cleaner
kerosene fuels.
Perkins T400012 Fuel Cleaner is the only fuel
cleaner that is recommended by Perkins .
Mixing alcohol or gasoline with diesel fuel can If biodiesel or biodiesel blends of fuel are to be used,
Perkins require the use of Perkins fuel cleaner. For
produce an explosive mixture in the engine crank- more information on the use of biodiesel and
case or the fuel tank. Alcohol or gasoline must biodiesel blends refer to “Biodiesel Fuel”.
not be used in order to dilute diesel fuel. Failure
to follow this instruction may result in death or Perkins fuel cleaner will remove deposits that can
personal injury. form in the fuel system with the use of biodiesel and
biodiesel blends. These deposits can create a loss of
power and engine performance.
There are many other diesel fuel specifications that
are published by governments and by technological Once the fuel cleaner has been added to the fuel, the
societies. Usually, those specifications do not review deposits within the fuel system are removed after 30
all the requirements that are addressed in table 17 . hours of engine operation. For maximum results,
To ensure optimum engine performance, a complete continue to use the fuel cleaner for up to 80 hours.
fuel analysis should be obtained before engine Perkins fuel cleaner can be used on an on-going
operation. The fuel analysis should include all of the basis with no adverse impact on engine or fuel
properties that are stated in the table 17 . system durability.
Detailed instructions on the rate of which the fuel
Aftermarket Fuel Additives cleaner must be use are on the container.
• Fuel economy (through fuel system cleanup) • Use high-quality fuels per recommended and
required specifications
• Lubricity
• Fill fuel tanks with fuels of “ISO 18/16/13”
• Oxidation stability cleanliness level or cleaner, in particular for
engines with common rail and unit injection
• Detergency/dispersancy systems. When you refuel the tank, filter the fuel
through a 4 µm absolute filter (Beta 4 = 75 up to
• Moisture dispersancy
200) in order to reach the recommended
• Corrosion protection cleanliness level. This filtration should be located
at the device that dispenses the fuel to the fuel
• Cetane (typically 2-3 cetane numbers) tank. In addition, filtration at the dispensing point
should remove water to ensure that fuel is
The diesel fuel conditioner also reduces the formation dispensed at 500 ppm water or less.
of gums, resins, and sludge, and disperses insoluble
gums. • Perkins recommends the use of bulk fuel filter /
For maximum overall benefits, ask your fuel supplier coalescer units which clean the fuel of both
to add the fuel conditioner at the recommended treat particulate contamination and water in a single
rate before fuel delivery. Or you may add the fuel pass.
conditioner at the recommended treat rate during the
early weeks of fuel storage. • Ensure that you use Perkins Advanced Efficiency
Fuel Filters . Change your fuel filters per
Contamination Control recommended service requirements or as needed.
Recommendations for Fuels • Drain your water separators daily .
Fuels of “ISO 18/16/13” cleanliness level or cleaner • Drain your fuel tanks of sediment and water per
as dispensed into the engine or application fuel tank
should be used. Reduce power loss, failures, and the Operation and Maintenance Manual
related down time of engines will result. This instructions.
cleanliness level is important for new fuel system
designs such as common rail injection systems and • Install and maintain a properly designed bulk filter /
unit injection systems. Injection system designs utilize coalescer filtration system. Continuous bulk
higher fuel pressures and tight clearances between filtration systems may be required to ensure that
moving parts in order to meet required stringent dispensed fuel meets the cleanliness target.
emissions regulations. Peak injection pressures in Consult your Perkins distributor for availability of
current fuel injection systems may exceed 30,000 psi. bulk filtration products.
Clearances in these systems are less than 5 µm. As a
result, particle contaminants as small as 4 µm can • Centrifugal filters may need to be used as a pre-
cause scoring and scratching of internal pump and filter with fuel that is severely contaminated with
injector surfaces and of injector nozzles. gross amounts of water and/or large particulate
contaminants. Centrifugal filters can effectively
Water in the fuel causes cavitation, corrosion of fuel remove large contaminants, but may not be able to
system parts, and provides an environment where
microbial growth in the fuel can flourish. Other remove the small abrasive particles required to
sources of fuel contamination are soaps, gels, or achieve the recommended “ISO” cleanliness level.
other compounds that may result from undesirable Bulk filter / coalescers are necessary as a final
chemical interactions in the fuels, particularly in filter in order to achieve the recommended
ULSD. Gels and other compounds can also form in cleanliness level.
biodiesel fuel at low temperatures or if biodiesel is
stored for extended periods. The best indication of • Install desiccant type breathers of 4 µm or less
microbial contamination, fuel additives, or cold absolute efficiency with the ability to remove water
temperature gel is rapid filter plugging of bulk fuel on bulk storage tanks.
filters or application fuel filters.
• Follow proper practices of fuel transportation.
In order to reduce downtime due to contamination, Filtration from the storage tank to the application
follow these fuel maintenance guidelines. promotes the delivery of clean fuel. Fuel filtration
can be installed at each transport stage in order to
keep the fuel clean.
• Cover, protect, and ensure cleanliness of all
connection hoses, fittings, and dispensing nozzles.
60 SEBU9070
Refill Capacities
Fluid Recommendations
Engine Oil
To relieve pressure from the lubricating system, turn
Coolant System off the engine.
i05963859
Pressurized system: Hot coolant can cause seri- Welding on Engines with
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve Electronic Controls
the pressure.
The engine can have the ability to auto start. Ensure NOTICE
that the power supply is isolated before any service or Because the strength of the frame may decrease,
repair is performed. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Perkins distributor regarding welding on
off the engine. Allow the cooling system pressure cap a chassis frame or rail.
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure.
Proper welding procedures are necessary in order to
Fuel System avoid damage to the engines ECM, sensors, and
associated components. When possible, remove the
To relieve the pressure from the fuel system, turn off component from the unit and then weld the
the engine. component. If removal of the component is not
possible, the following procedure must be followed
High Pressure Fuel Lines when you weld on a unit equipped with an Electronic
Engine. The following procedure is considered to be
the safest procedure to weld on a component. This
procedure should provide a minimum risk of damage
to electronic components.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel NOTICE
spray may cause a fire hazard. Failure to follow Do not ground the welder to electrical components
these inspection, maintenance and service in- such as the ECM or sensors. Improper grounding can
structions may cause personal injury or death. cause damage to the drive train bearings, hydraulic
components, electrical components, and other
components.
The high pressure fuel lines are the fuel lines that are
between the high pressure fuel pump and the high Clamp the ground cable from the welder to the com-
pressure fuel manifold and the fuel lines that are ponent that will be welded. Place the clamp as close
between the fuel manifold and cylinder head. These as possible to the weld. This will help reduce the pos-
fuel lines are different from fuel lines on other fuel sibility of damage.
systems.
This is because of the following differences: Note: Perform the welding in areas that are free from
explosive hazards.
• The high pressure fuel lines are constantly
charged with high pressure. 1. Stop the engine. Turn the switched power to the
• The internal pressures of the high pressure fuel OFF position.
lines are higher than other types of fuel system.
62 SEBU9070
Maintenance Recommendations
Welding on Engines with Electronic Controls
• ECM
• Sensors
• Relays
NOTICE
Do not use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.
Illustration 31 g01075639
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being welded
and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
7. Use standard welding practices to weld the Quality of the air – The engine may be exposed to
materials. extended operation in an environment that is dirty or
dusty, unless the equipment is cleaned regularly.
Mud, dirt, and dust can encase components.
i04150276
Maintenance can be difficult. The buildup can contain
corrosive chemicals.
Severe Service Application
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
Severe service is the application of an engine that settings for that application. Necessary adjustments
exceeds the current published standards for that should be made.
engine. Perkins maintains standards for the
following engine parameters:
Incorrect Operating Procedures
• Performance such as power range, speed range,
and fuel consumption • Extended operation at low idle
Environmental Factors
Ambient temperatures – The engine may be
exposed to extended operation in cold environments
or hot environments. Valve components can be
damaged by carbon buildup if the engine is frequently
started and stopped in cold temperatures. Hot intake
air reduces engine performance.
64 SEBU9070
Maintenance Recommendations
Maintenance Interval Schedule
“Fuel Tank Water and Sediment - Drain” .................84 “Water Pump - Inspect”............................................88
i05963992
4. Wash the core with hot, soapy water.
Aftercooler Core - Inspect/
5. Flush the core thoroughly in order to remove
Clean/Test residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the
core is clear and free of debris.
Inspect
Inspect the aftercooler for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the aftercooler, if necessary. Personal injury can result from air pressure.
Inspect these items for good condition: welds, Personal injury can result without following prop-
mounting brackets, oil lines, water lines, connections, er procedure. When using pressure air, wear a
clamps and seals. Make repairs, if necessary. protective face shield and protective clothing.
Inspect the fins for damage. Bent fins may be opened The maximum air pressure for cleaning purposes
with a “comb”. must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
Clean
6. Dry the core with compressed air. Direct the air in
Note: Adjust the frequency of cleaning according to the reverse direction of the normal flow.
the effects of the operating environment. Clean and
test the aftercooler every 4000 service hours unless Test
the inspection indicates the need for more frequent
cleaning. 1. Inspect the core for trapped debris and cleanliness.
If necessary, remove the debris and repeat the
Remove the core. Refer to the Disassembly and
Assembly Manual for the procedure. cleaning procedure.
1. Place the aftercooler on the side in order to remove 2. Inspect the core for damage and perform a
debris Remove the debris that is accessible. pressure test in order to detect leaks. Many shops
that service radiators are equipped to perform
pressure tests.
NOTICE
Do not use a high concentration of caustic cleaner to 3. Plug both ends of the aftercooler core and
clean the core. A high concentration of caustic pressurize the core to 205 kPa (30 psi). Submerge
cleaner can attack the internal metals of the core and the core in water. Look for bubbles which are being
cause leakage. Only use the recommended concen- emitted from the core. The bubbles are evidence of
tration of cleaner. leaks.
4. If any leaks are found, do not attempt to repair the
2. Back flush the core with cleaner.
core.
Table 18
Hydrosolv Liquid Cleaners(1) Install a core that is clean and that passes the
pressure test in step 3. Refer to the Disassembly and
Part Number Description Size Assembly Manual for the procedure.
i02322311
2. Turn off any battery chargers. Disconnect any
Alternator - Inspect battery chargers.
3. Ensure that the battery disconnect switch is in the
Perkins recommends a scheduled inspection of the OFF position.
alternator. Inspect the alternator for loose
connections and correct battery charging. Check the 4. Disconnect the NEGATIVE “-” cable from the
ammeter (if equipped) during engine operation in NEGATIVE “-” battery terminal.
order to ensure correct battery performance and/or
correct performance of the electrical system. Make 5. Disconnect the POSITIVE “+” cable from the
repairs, as required. POSITIVE “+” battery terminal.
Check the alternator and the battery charger for
correct operation. If the batteries are correctly Note: Always recycle a battery. Never discard a
charged, the ammeter reading should be very near battery. Dispose of used batteries to an appropriate
zero. All batteries should be kept charged. The recycling facility.
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold, 6. Remove the used battery.
the battery will not crank the engine. When the engine
is not run for long periods of time or if the engine is 7. Install the new battery.
run for short periods, the batteries may not fully
charge. A battery with a low charge will freeze more
Note: Before the cables are connected, ensure that
easily than a battery with a full charge.
the battery disconnect switch is in the OFF position.
8. Connect the POSITIVE “+” cable to the POSITIVE
i05425759
“+” battery terminal.
Battery - Replace 9. Connect the NEGATIVE “-” cable to the
NEGATIVE “-” battery terminal.
1. Switch the engine to the OFF position. Remove all 1. Remove the filler caps. Maintain the electrolyte
electrical loads. level to the “FULL” mark on the battery.
Note: After the engine has stopped, allow 2 minutes If the addition of water is necessary, use distilled
in order for the diesel exhaust fluid lines to be purged water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
before disconnecting the power. softened water.
SEBU9070 67
Maintenance Recommendations
Battery or Battery Cable - Disconnect
2. Check the condition of the electrolyte with a 7. Proceed with necessary system repairs.
suitable battery tester.
8. In order to connect the battery, connect the positive
3. Install the caps. connection before the negative connector.
i02323088
1. Turn the start switch to the OFF position. Turn the Remove the belt. Refer to Disassembly and
ignition switch (if equipped) to the OFF position Assembly, “Alternator Belt - Remove and Install”.
and remove the key and all electrical loads.
Ensure that the belt tensioner is securely installed.
Visually inspect the belt tensioner (1) for damage.
2. Disconnect the negative battery terminal. Ensure
Check that the pulley on the tensioner rotates freely
that the cable cannot contact the terminal. When and that the bearing is not loose.
four 12 volt batteries are involved, two negative
connection must be disconnected.
i05984651
3. Remove the positive connection.
Belts - Inspect/Adjust
4. Clean all disconnected connection and battery
terminals.
To maximize the engine performance, inspect the belt
5. Use a fine grade of sandpaper to clean the for wear and for cracking. Replace the belt if the belt
terminals and the cable clamps. Clean the items is worn or damaged.
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal of Fan Belts
material can cause the clamps to not fit correctly.
Coat the clamps and the terminals with a suitable • Inspect each belt for cracks, splits, glazing,
grease, displacement of the cord and evidence of
silicone lubricant or petroleum jelly.
fluid contamination.
6. Tape the cable connections in order to help prevent
accidental starting.
68 SEBU9070
Maintenance Recommendations
Belts - Inspect/Adjust
Fan Belts Adjust 1. Tighten nuts (5) and (7) securely. Tighten bolts (1)
and (2), also tighten nut (3). Tighten nut and bolts
to a torque of 89 N·m (65 lb ft). Tighten bolt (4) to a
torque of 100 N·m (73 lb ft).
Illustration 33 g03748150
Typical example
Illustration 35 g03748152
Typical example
i05985305
Fill
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.
Illustration 37 g03748670 2. Start and run the engine until normal operating
temperature. Stop the engine.
2. Remove drain plug (1). Also, remove the drain plug
from the radiator. 3. Maintain the coolant level at the maximum mark
that is correct for your application.
Allow the coolant to drain.
4. Clean the cooling system filler cap. Inspect the
For information regarding the disposal and the gasket that is on the cooling system filler cap. If the
recycling of used coolant, consult your Perkins
distributor. gasket that is on the cooling system filler cap is
damaged, discard the old cooling system filler cap
Flush and install a new cooling system filler cap. If the
gasket that is on the cooling system filler cap is not
1. Flush the cooling system with clean water in order damaged, pressure test the cooling system filler
to remove any debris. cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
NOTICE system filler cap. If the cooling system filler cap
Do not fill the cooling system faster than 5 L does not retain the correct pressure, install a new
(1.3 US gal) per minute to avoid air locks. cooling system filler cap.
Cooling system air locks may result in engine 5. Start the engine. Inspect the cooling system for
damage. leaks and for proper operating temperature.
2. Fill the cooling system with clean water. Install the i05197396
i05966993
Illustration 39 g02590196
Illustration 38 g00285520
Typical filler cap gaskets
Cooling system filler cap
3. Clean the cooling system filler cap and check the
condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are
Pressurized System: Hot coolant can cause seri- damaged. Reinstall the cooling system filler cap.
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system 4. Inspect the cooling system for leaks.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the i05975694
pressure.
Coolant Temperature
1. Remove the cooling system filler cap slowly in Regulator - Replace
order to relieve pressure.
Refer to Disassembly and Assembly, “Water • The damper is dented, cracked, or fluid is leaking
Temperature Regulator Housing - Remove and from the damper.
Install” for the replacement procedure of the water
temperature regulator, or consult your Perkins • The paint on the damper is discolored from
distributor. excessive heat.
Note: If only the water temperature regulators are • The damper is bent.
replaced, drain the coolant from the cooling system to
a level that is below the housing. • The bolt holes are worn or there is a loose fit for
the bolts.
i05967790
• The engine has had a crankshaft failure due to
torsional forces.
Crankshaft Vibration Damper -
Replace the damper if any of these conditions exist.
Inspect
Ensure that the cooling fins (2) are clean and free
from damage.
Damage to the crankshaft vibration damper or failure
of the crankshaft vibration damper can increase Removal and Installation
torsional vibrations. This torsional vibration can result
in damage to the crankshaft and to other engine Refer to the Disassembly and Assembly Manual,
components. A deteriorating damper can cause “Vibration Damper and Pulley - Remove and Install”
excessive gear train noise at variable points in the for information on removing and installing the damper.
speed range.
i02151646
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the
engine. Driven Equipment - Check
• Adjustment
• Lubrication
i02568158
Engine - Clean
Illustration 40 g03741828
Typical example
(1) Vibration damper Personal injury or death can result from high
(2) Cooling fins
voltage.
NOTICE
Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
fluid spills whenever a significant quantity accumu-
lates on the engine.
• Ease of maintenance
Note: Caution must be used in order to prevent
electrical components from being damaged by
excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the Electronic Control Module (ECM).
Illustration 41 g03748730
i05985308 1. Remove the six clips (2) and remove the cover (3).
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to en-
gine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
Illustration 42 g03748780
NOTICE
Never service the air cleaner element with the engine 2. Remove element (5) and discard old element.
running since this will allow dirt to enter the engine.
3. Ensure that the cover (3) cap (1) and valve (4) are
clean and free from dirt.
4. Install new element (5), install cover (3). Install
clips (2). Insure that valve (4) is vertically down.
i05967801
i05967836
i05967804
i02323089
2. Loosen hose clamp (3) and remove hose (4) from Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
breather assembly (6).
contact the skin.
3. Remove bolt (2) and the washer (1). Remove the
breather assembly (6) from housing (5).
1. Maintain the oil level between the “ADD” mark (Y) Obtain the Sample and the Analysis
and the “FULL” mark (X) on the engine oil
dipstick. Do not fill the crankcase above the
“FULL” mark (X).
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
NOTICE contact the skin.
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 In order to help obtain the most accurate analysis,
dipping into the oil reduces the oil's lubricating char- record the following information before an oil sample
acteristics and could result in the loss of power. is taken:
• The date of the sample
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap. • Engine model
• Engine number
i05969787
• Service hours on the engine
Engine Oil Sample - Obtain
• The number of hours that have accumulated since
the last oil change
The condition of the engine lubricating oil may be • The amount of oil that has been added since the
checked at regular intervals as part of a preventive last oil change
maintenance program. Perkins include an oil
sampling valve (1) as an option. The oil sampling Ensure that the container for the sample is clean and
valve is included in order to sample regularly the dry. Also ensure that the container for the sample is
engine lubricating oil. clearly labeled.
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, mixed well oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
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.
i05969790
Illustration 47 g03742403
Typical example Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
Perkins recommends using a sampling valve in order contact the skin.
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.
78 SEBU9070
Maintenance Recommendations
Engine Oil and Filter - Change
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.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
2. Start the engine and run the engine for 2 minutes. Refer to Systems Operation, Testing and Adjusting,
Perform this procedure in order to ensure that the “Engine Valve Lash - Inspect/Adjust” for more
information.
lubrication system has oil and that the oil filter is
filled. Inspect the oil filter for oil leaks.
i06023929
3. Stop the engine and allow the oil to drain back to
the sump for a minimum of 10 minutes. Fan Clearance - Check
4. Remove the oil level gauge in order to check the oil
level. Maintain the oil level between the “Low” and Ensure that the engine is stopped and that the battery
“High” marks on the oil level gauge. disconnect switch is in the OFF position.
Ensure that the radiator is full of the correct coolant.
i05969949
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.
Operation of Perkins engines with incorrect valve
lash can reduce engine efficiency, and also reduce
engine component life.
Illustration 49 g03779353
Typical example
1. The clearance between the cover (1) and the fan If necessary, perform minor adjustments. Repair any
(2) must be checked at four equal distances. leaks from the fuel system and from the cooling,
Measure the distance between the fan tip and the lubrication, or air systems. Ensure that all
adjustments and repairs are performed by authorized
edge of the cover. personnel that have had the correct training.
2. The gap (A) must be between 8 to 10 mm The fuel system should be primed under the
(0.31 to 0.39 inch). following conditions:
i05969962
• The fuel tank is empty or the fuel tank has been
partially drained.
Fuel System - Prime • The engine has been in storage.
• The fuel filter has been replaced.
Fuel leaked or spilled onto hot surfaces or electri- 1. Ensure that the key switch is in the OFF position.
cal components can cause a fire. To help prevent Ensure that the fuel tank is full of clean diesel fuel.
possible injury, turn the start switch off when Check that the fuel supply valve (if equipped) is in
changing fuel filters or water separator elements. the “ON” position.
Clean up fuel spills immediately.
i05970884
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
Illustration 50 g03742605
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
6. Turn the valves for the fuel lines (if equipped) to the
ON position. Prime the fuel system. Refer to the
Operation and Maintenance Manual, “Fuel System
- Prime” for more information.
The primary fuel filter and the secondary fuel filter
should be serviced together.
i05970923
Illustration 51 g03742960
2. Pace a suitable container below the primary fuel Fuel leaked or spilled onto hot surfaces or electri-
filter. Drain the fuel from the primary fuel filter. cal components can cause a fire. To help prevent
Open the drain valve (1) and allow the fluid to possible injury, turn the start switch off when
drain. Then, close the drain valve. changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
Illustration 52 g03742961
Illustration 53 g03742960
i05970937
The primary fuel filter and the secondary fuel filter Fuel Storage Tanks
should be serviced together.
Drain the water and the sediment from the fuel
storage tank at the following intervals:
i02568194
• Service intervals
Fuel Tank Water and Sediment
• Refill of the tank
- Drain
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank.
NOTICE
If a bulk storage tank has been refilled or moved
Care must be taken to ensure that fluids are con- recently, allow adequate time for the sediment to
tained during performance of inspection, mainte- settle before filling the engine fuel tank. Internal
nance, testing, adjusting and repair of the product. Be baffles in the bulk storage tank will also help trap
prepared to collect the fluid with suitable containers sediment. Filtering fuel that is pumped from the
before opening any compartment or disassembling storage tank helps to ensure the quality of the fuel.
any component containing fluids. When possible, water separators should be used.
Dispose of all fluids according to local regulations and
mandates. i05970985
The electronics grounding stud must have a wire Due to extreme temperature changes, the hose will
ground to the battery. Tighten the electronics heat set. Heat setting causes hose clamps to loosen.
grounding stud at every oil change. Ground wires and This action can result in leaks. A constant torque
straps should be combined at engine grounds. All hose clamp will help to prevent loose hose clamps.
grounds should be tight and free of corrosion.
Each installation application can be different. The
• Clean the electronics grounding stud and the differences depend on the following factors:
terminals for the ground strap with a clean cloth.
• Type of hose
• If the connections are corroded, clean the
connections with a solution of baking soda and • Type of fitting material
water.
• Anticipated expansion and contraction of the hose
• Keep the electronics grounding stud and the strap
• Anticipated expansion and contraction of the
clean and coated with MPGM grease or petroleum
fittings
jelly.
Replace the Hoses and the Clamps
i05971027
Replace hoses that are cracked or soft. Tighten any
Hoses and Clamps - Inspect/ loose clamps. For information on replacing hoses and
clamps refer to the Disassembly and Assembly
Replace Manual.
i05971073
Inspect all hoses for leaks that are caused by the
following conditions: Jacket Water Heater - Check
• Cracking
• Outer covering that is chafed or cut For an overhaul solution, contact your Perkins
distributor.
• Exposed wire that is used for reinforcement
i05971137
• Outer covering that is ballooning locally
i02568203
2. Turn the compressor wheel and the turbine wheel Inspect the Engine for Leaks and
by hand. The assembly should turn freely. Inspect for Loose Connections
the compressor wheel and the turbine wheel for
A walk-around inspection should only take a few
contact with the turbocharger housing. There
minutes. When the time is taken to perform these
should not be any visible signs of contact between checks, costly repairs and accidents can be avoided.
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of For maximum engine service life, make a thorough
contact between the rotating turbine wheel or the inspection of the engine compartment before starting
compressor wheel and the turbocharger housing, the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and
the turbocharger must be reconditioned. trash buildup. Make repairs, as needed:
3. Check the compressor wheel for cleanliness. If • The guards must be in the proper place. Repair
only the blade side of the wheel is dirty, dirt and/or damaged guards or replace missing guards.
moisture is passing through the air filtering system.
If oil is found only on the back side of the wheel, • Wipe all caps and plugs before the engine is
there is a possibility of a failed turbocharger oil serviced in order to reduce the chance of system
contamination.
seal.
The presence of oil may be the result of extended NOTICE
engine operation at low idle. The presence of oil For any type of leak (coolant, lube, or fuel) clean up
may also be the result of a restriction of the line for the fluid. If leaking is observed, find the source and
the inlet air (plugged air filters), which causes the correct the leak. If leaking is suspected, check the flu-
turbocharger to slobber. id levels more often than recommended until the leak
is found or fixed, or until the suspicion of a leak is
4. Use a dial indicator to check the end clearance on proved to be unwarranted.
the shaft. If the measured end play is greater than
the Service Manual specifications, the
turbocharger should be repaired or replaced. An NOTICE
end play measurement that is less than the Accumulated grease and/or oil on an engine or deck
minimum Service Manual specifications could is a fire hazard. Remove this debris with steam clean-
indicate carbon buildup on the turbine wheel. The ing or high pressure water.
turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less
• Ensure that the cooling lines are properly clamped
than the minimum Service Manual specifications. and that the cooling lines are tight. Check for
leaks. Check the condition of all pipes.
5. Inspect the bore of the turbine housing for
corrosion. • Inspect the water pumps for coolant leaks.
6. Clean the turbocharger housing with standard shop Note: The water pump seal is lubricated by coolant in
solvents and a soft bristle brush. the cooling system. It is normal for a small amount of
leakage to occur as the engine cools down and the
7. Fasten the air inlet piping and the exhaust outlet parts contract.
piping to the turbocharger housing.
Excessive coolant leakage may indicate the need to
replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/
or seals, refer to the Service Manual for the engine or
consult your Perkins distributor.
88 SEBU9070
Maintenance Recommendations
Water Pump - Inspect
• Inspect the lubrication system for leaks at the front Visually inspect the water pump for leaks. If any
crankshaft seal, the rear crankshaft seal, the oil leaking is observed, replace the water pump seal or
pan, the oil filters and the valve cover. the water pump assembly. Refer to the Service
Manual for the disassembly and assembly procedure.
• Inspect the fuel system for leaks. Look for loose
fuel line clamps or for loose fuel line tie-wraps. Note: Refer to the Service Manual or consult your
Perkins distributor if any repair is needed or any
• Inspect the piping for the air inlet system and the replacement is needed.
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
• Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
• Drain the water and the sediment from fuel tanks
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.
• Inspect the ECM to the cylinder head ground strap
for a good connection and for good condition.
i02568235
Warranty Section
Warranty Information
i01903596
Emissions Warranty
Information
NOTICE
Operating engines above the rating definitions can re-
sult in shorter service life before overhaul.
92 SEBU9070
Reference Materials
Maintenance Records
Reference Materials
i05204672
Maintenance Records
• Maintenance log
SEBU9070 93
Reference Materials
Maintenance Log
i05204675
Maintenance Log
Table 20
Engine Model Customer Identifier
Service Quantity Of
Service Item Date Authorization
Hours Fuel
94 SEBU9070
Reference Materials
Reference Material
i05204677
Reference Material
(Extended Service Contract)
NOTICE
Dependant upon engine type and application.
SEBU9070 95
Index Section
Index
A Crushing Prevention and Cutting Prevention .. 12
After Starting Engine........................................ 40
After Stopping Engine...................................... 44 D
Aftercooler Core - Inspect/Clean/Test.............. 65
Clean............................................................ 65 Diagnostic Lamp.............................................. 35
Inspect ......................................................... 65 Driven Equipment - Check............................... 73
Test .............................................................. 65
Air Shutoff - Test .............................................. 65 E
Alternator - Inspect .......................................... 66
Electrical System ............................................. 13
Grounding Practice ...................................... 14
B Emergency Stopping ....................................... 44
Battery - Replace............................................. 66 Emissions Certification Film ............................ 23
Battery Electrolyte Level - Check .................... 66 Emissions Warranty Information...................... 89
Battery or Battery Cable - Disconnect ............. 67 Engaging the Driven Equipment...................... 41
Before Starting Engine ...............................12, 37 Engine - Clean ................................................. 73
Belt Tensioner - Check..................................... 67 Engine Air Cleaner Element (Single
Belts - Inspect/Adjust....................................... 67 Element) - Inspect/Replace ........................... 74
Coolant Pump Drive Belt.............................. 68 Engine Air Cleaner Service Indicator -
Fan Belts...................................................... 67 Inspect (If Equipped)...................................... 75
New belts ..................................................... 68 Engine Air Precleaner - Check/Clean (If
Belts - Replace ................................................ 69 Equipped) ...................................................... 75
Burn Prevention............................................... 10 Engine Crankcase Breather - Clean................ 75
Batteries....................................................... 10 Engine Diagnostics.......................................... 35
Coolant......................................................... 10 Engine Electronics........................................... 14
Diesel Fuel ................................................... 10 Engine Mounts - Inspect.................................. 76
Oils............................................................... 10 Engine Oil and Filter - Change ........................ 77
Drain the Engine Oil ..................................... 78
Fill the Engine Crankcase ............................ 78
C Replace the Oil Filter.................................... 78
Engine Oil Level - Check ................................. 76
Cold Weather Operation.................................. 42
Engine Oil Sample - Obtain ............................. 77
Cold Weather Starting ............................... 37–38
Obtain the Sample and the Analysis............ 77
Configuration Parameters................................ 36
Engine Operation............................................. 41
System Configuration Parameters............... 36
Engine Operation with Active Diagnostic
Coolant (DEAC) - Change ............................... 69
Codes ............................................................ 35
Drain ............................................................ 69
Engine Operation with Intermittent
Fill................................................................. 70
Diagnostic Codes........................................... 35
Flush ............................................................ 69
Engine Rating Conditions................................ 90
Coolant (ELC) - Change .................................. 70
Engine Rating Definitions ................................ 90
Drain ............................................................ 70
Engine Ratings ................................................ 90
Fill................................................................. 71
Engine Starting ...........................................13, 37
Flush ............................................................ 71
Engine Stopping .........................................13, 44
Coolant Extender (ELC) - Add ......................... 71
Engine Valve Lash - Check.............................. 79
Coolant Level - Check ..................................... 72
Coolant Temperature Regulator - Replace ...... 72
Crankshaft Vibration Damper - Inspect............ 73 F
Inspection..................................................... 73
Removal and Installation.............................. 73 Fan Clearance - Check.................................... 79
96 SEBU9070
Index Section
R
Radiator - Clean............................................... 85
Radiator Restrictions ....................................... 42
Reference Information..................................... 23
Record for Reference................................... 23
Reference Information Section ........................ 90
Reference Material (Extended Service
Contract) ........................................................ 94
Reference Materials ........................................ 92
Refill Capacities............................................... 45
Cooling System............................................ 45
98 SEBU9070
Index Section
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:
Transmission
Serial Number:
Attachment Information:
Dealer Equipment
Number:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
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All Rights Reserved
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