SEBU7853

July 2003

Operation and
Maintenance
Manual
800 Industrial Engine
UE11-Up (Machine)
UF11-Up (Machine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Perkins
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Perkins dealers have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents Index Section

Index ..................................................................... 70
Foreword ................................................................. 4

Safety Section
Safety Signs and Labels ......................................... 6

General Hazard Information ................................... 8

Burn Prevention ...................................................... 9

Fire Prevention and Explosion Prevention ............ 10

Crushing Prevention and Cutting Prevention ........ 12

Before Starting Engine .......................................... 12

Engine Starting ..................................................... 12

Engine Stopping ................................................... 13

Electrical System .................................................. 13

Product Information Section

Model Views ......................................................... 14

Product Identification Information ........................ 19

Operation Section
Lifting and Storage ................................................ 21

Gauges and Indicators .......................................... 24

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

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

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

Cold Weather Operation ....................................... 30

Maintenance Section
Lubricant Specifications ........................................ 34

Fuel Specifications ................................................ 38

Cooling System Specifications ............................. 41

Refill Capacities .................................................... 47

Maintenance Interval Schedule ............................ 48

Warranty Section
Warranty Information ............................................ 69
4
Foreword

Foreword Use fuel consumption or service hours to determine

intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals
Literature Information if they provide more convenient schedules and
approximate the indicated service meter reading.
This manual contains safety, operation instructions,
lubrication and maintenance information. This Recommended service should be performed at the
manual should be stored in or near the engine area appropriate intervals as indicated in the Maintenance
in a literature holder or literature storage area. Read, Interval Schedule. The actual operating environment
study and keep it with the literature and engine of the engine also governs the Maintenance Interval
information. Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
English is the primary language for all Perkins more frequent lubrication and maintenance than is
publications. The English used facilitates translation specified in the Maintenance Interval Schedule may
and consistency in electronic media delivery. be necessary.
Some photographs or illustrations in this manual The maintenance schedule items are organized for
show details or attachments that may be different a preventive maintenance management program. If
from your engine. Guards and covers may have the preventive maintenance program is followed, a
been removed for illustrative purposes. Continuing periodic tune-up is not required. The implementation
improvement and advancement of product design of a preventive maintenance management program
may have caused changes to your engine which are should minimize operating costs through cost
not included in this manual. Whenever a question avoidances resulting from reductions in unscheduled
arises regarding your engine, or this manual, please downtime and failures.
consult with your Perkins dealer for the latest
available information.
Maintenance Intervals
Safety Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
This safety section lists basic safety precautions. items in each level should be shifted ahead or back
In addition, this section identifies hazardous, depending upon your specific maintenance practices,
warning situations. Read and understand the basic operation and application. We recommend that
precautions listed in the safety section before the maintenance schedules be reproduced and
operating or performing lubrication, maintenance and displayed near the engine as a convenient reminder.
repair on this product. We also recommend that a maintenance record be
maintained as part of the engine’s permanent record.
Operation
See the section in the Operation and Maintenance
Operating techniques outlined in this manual are Manual, “Maintenance Records” for information
basic. They assist with developing the skills and regarding documents that are generally accepted
techniques required to operate the engine more as proof of maintenance or repair. Your authorized
efficiently and economically. Skill and techniques Perkins dealer can assist you in adjusting your
develop as the operator gains knowledge of the maintenance schedule to meet the needs of your
engine and its capabilities. operating environment.

The operation section is a reference for operators. Overhaul

Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating Major engine overhaul details are not covered in the
and stopping the engine. This section also includes a Operation and Maintenance Manual except for the
discussion of electronic diagnostic information. interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
Maintenance an authorized Perkins dealer. Your Perkins
dealer offers a variety of options regarding overhaul
The maintenance section is a guide to engine care. programs. If you experience a major engine failure,
The illustrated, step-by-step instructions are grouped there are also numerous after failure overhaul options
by fuel consumption, service hours and/or calendar available from your Perkins dealer. Consult with
time maintenance intervals. Items in the maintenance your dealer for information regarding these options.
schedule are referenced to detailed instructions that
follow.
 5
Foreword

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.

Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.
6
Safety Section
Safety Signs and Labels

Safety Section
i01933317

Safety Signs and Labels

There may be several specific warning signs on

an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiar with all warning
signs.

Ensure that all of the warning signs are legible. Clean

the warning signs or replace the warning signs if
the words cannot be read or if the pictures are not
visible. When the warning signs are cleaned, use a
cloth, water, and soap. Do not use solvent, gasoline,
or other harsh chemicals to clean the warning signs.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the warning signs. The
warning signs that are loosened could drop off of
the engine.

Replace any damaged warning signs or missing

warning signs. If a warning sign is attached to a part
of the engine that is replaced, install a new warning
sign on the replacement part. Any Perkins dealer
or any Perkins distributor can provide new warning
signs.

Do not work on the engine and do not operate the

engine unless the instructions and warnings in the
Operation and Maintenance Manual are understood.
Proper care is your responsibility. Failure to follow
the instructions or failure to heed the warnings could
result in injury or in death.

The warning labels that may be found on the engine

are illustrated and described.
 7
Safety Section
Safety Signs and Labels

g01000440
Illustration 1
8
Safety Section
General Hazard Information

Do Not Operate Before Reading the i01884947

Manual (1) General Hazard Information

This message is located on the side of the valve
cover.

g00104545
g00934493 Illustration 2

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

warning tag to the start switch or to the controls
before you service the equipment or before you
Do not operate or work on this engine unless you repair the equipment.
have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Perkins dealer for replacement manuals.
Proper care is your responsibility.

Starting Aid (2)

The warning label for the starting aid is located on
top of the air inlet manifold.

g00702020
Illustration 3

Wear a hard hat, protective glasses, and other

protective equipment, as required.

Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

Make sure that all protective guards and all covers

are secured in place on the engine.

g00283559 Keep the engine free from foreign material. Remove

debris, oil, tools, and other items from the deck, from
walkways, and from steps.

Never put maintenance fluids into glass containers.

If equipped with an air inlet heater (AIH) for cold Drain all liquids into a suitable container.
weather starting, do not use aerosal types of start-
ing aids such as ether. Such use could result in an Obey all local regulations for the disposal of liquids.
explosion and personal injury.
 9
Safety Section
Burn Prevention

Use all cleaning solutions with care. Report all Always use a board or cardboard when you check
necessary repairs. for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
Do not allow unauthorized personnel on the serious injury and possible death. A pin hole leak can
equipment. cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
Unless you are instructed otherwise, perform from a doctor that is familiar with this type of injury.
maintenance on the engine with the equipment in
the servicing position. Refer to the OEM information
for the procedure for placing the equipment in the
Containing Fluid Spillage
servicing position.
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
Pressure Air and Water maintenance, testing, adjusting and repair of the
engine. Make provision to collect the fluid with a
Pressurized air and/or water can cause debris suitable container before any compartment is opened
and/or hot water to be blown out. This could result in or before any component is disassembled.
personal injury.
• Only use the tools that are suitable for collecting
When pressurized air and/or water is used for fluids and equipment that is suitable for collecting
cleaning, wear protective clothing, protective shoes, fluids.
and eye protection. Eye protection includes goggles
or a protective face shield. • Only use the tools that are suitable for containing
fluids and equipment that is suitable for containing
The maximum air pressure for cleaning purposes fluids.
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below Obey all local regulations for the disposal of liquids.
275 kPa (40 psi).
i01480768
Fluid Penetration
Burn Prevention
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly. Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
Do not remove any hydraulic components or parts is performed on the engine. Relieve all pressure
until pressure has been relieved or personal injury in the air system, in the hydraulic system, in the
may occur. Do not disassemble any hydraulic lubrication system, in the fuel system, or in the
components or parts until pressure has been relieved cooling system before any lines, fittings or related
or personal injury may occur. Refer to the OEM items are disconnected.
information for any procedures that are required to
relieve the hydraulic pressure. Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause

severe burns. Allow cooling system components to
cool before the cooling system is drained.

Check the coolant level after the engine has stopped

and the engine has been allowed to cool.

Ensure that the filler cap is cool before removing the

g00687600 filler cap. The filler cap must be cool enough to touch
Illustration 4
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
10
Safety Section
Fire Prevention and Explosion Prevention

Cooling system conditioner contains alkali. Alkali can If the application involves the presence of combustible
cause personal injury. Do not allow alkali to contact gases, consult your Perkins dealer and/or your
the skin, the eyes, or the mouth. Perkins distributor for additional information about
suitable protection devices.
Oils Remove all flammable materials such as fuel, oil, and
Hot oil and hot lubricating components can cause debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin. Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
Batteries containers. Do not smoke in areas that are used for
storing flammable materials.
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or Do not expose the engine to any flame.
the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries Exhaust shields (if equipped) protect hot exhaust
and connectors. Use of gloves is recommended. components from oil or fuel spray in case of a line,
a tube, or a seal failure. Exhaust shields must be
installed correctly.
i01885715

Fire Prevention and Explosion Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
Prevention flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.

Wiring must be kept in good condition. All electrical

wires must be properly routed and securely attached.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.

Arcing or sparking could cause a fire. Secure

g00704000
connections, recommended wiring, and properly
Illustration 5 maintained battery cables will help to prevent arcing
or sparking.
All fuels, most lubricants, and some coolant mixtures
are flammable. Inspect all lines and hoses for wear or for
deterioration. The hoses must be properly routed.
Flammable fluids that are leaking or spilled onto hot The lines and hoses must have adequate support
surfaces or onto electrical components can cause and secure clamps. Tighten all connections to the
a fire. Fire may cause personal injury and property recommended torque. Leaks can cause fires.
damage.
Oil filters and fuel filters must be properly installed.
A flash fire may result if the covers for the engine The filter housings must be tightened to the proper
crankcase are removed within fifteen minutes after torque.
an emergency shutdown.

Determine whether the engine will be operated in an

environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
 11
Safety Section
Fire Prevention and Explosion Prevention

Improper jumper cable connections can cause

an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.

Do not charge a frozen battery. This may cause an

explosion.

The batteries must be kept clean. The covers

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

Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
g00704059
Illustration 6
Lines, Tubes and Hoses
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not Do not bend high pressure lines. Do not strike high
refuel an engine near open flames or sparks. Always pressure lines. Do not install any lines that are bent
stop the engine before refueling. or damaged.

Repair any lines that are loose or damaged. Leaks

can cause fires. Consult your Perkins dealer for
repair or for replacement parts.

Check lines, tubes and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.

Replace the parts if any of the following conditions

are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.

g00704135
• Flexible part of the hoses are kinked.
Illustration 7
• Outer covers have embedded armoring.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do • End fittings are displaced.
not smoke in battery charging areas.
Make sure that all clamps, guards, and heat shields
Never check the battery charge by placing a metal are installed correctly. During engine operation, this
object across the terminal posts. Use a voltmeter or will help to prevent vibration, rubbing against other
a hydrometer. parts, and excessive heat.
12
Safety Section
Crushing Prevention and Cutting Prevention

i01359666 All protective guards and all protective covers must

be installed if the engine must be started in order
Crushing Prevention and to perform service procedures. To help prevent an
Cutting Prevention accident that is caused by parts in rotation, work
around the parts carefully.

Do not bypass the automatic shutoff circuits. Do not

Support the component properly when work beneath disable the automatic shutoff circuits. The circuits are
the component is performed. provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
Unless other maintenance instructions are provided, engine damage.
never attempt adjustments while the engine is
running. See the Service Manual for repairs and for
adjustments.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance i01933350
is performed. After the maintenance is performed,
reinstall the guards. Engine Starting
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.

When objects are struck, wear protective glasses in

order to avoid injury to the eyes.
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
Chips or other debris may fly off objects when objects
personal injury.
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
i01805780
the controls. Consult with the person that attached
Before Starting Engine the warning tag before the engine is started.

All protective guards and all protective covers must

be installed if the engine must be started in order
to perform service procedures. To help prevent an
NOTICE
accident that is caused by parts in rotation, work
For initial start-up of a new or rebuilt engine, and for around the parts carefully.
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
Start the engine from the operator’s compartment or
occur. This may be accomplished by shutting off the from the engine start switch.
air and/or fuel supply to the engine.
Always start the engine according to the procedure
Overspeed shutdown should occur automatically. that is described in the Operation and Maintenance
If automatic shutdown does not occur, press the Manual, “Engine Starting” topic in the Operation
emergency stop button in order to cut the fuel and/or Section. Knowing the correct procedure will help to
air to the engine. prevent major damage to the engine components.
Knowing the procedure will also help to prevent
Inspect the engine for potential hazards. personal injury.

Before starting the engine, ensure that no one is on, To ensure that the jacket water heater (if equipped)
underneath, or close to the engine. Ensure that the and/or the lube oil heater (if equipped) is working
area is free of personnel. properly, check the water temperature gauge and the
oil temperature gauge during the heater operation.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all Engine exhaust contains products of combustion
lights work properly, if equipped. which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
 13
Safety Section
Engine Stopping

Note: The engine is equipped with an automatic Grounding Practices

device for cold starting for normal conditions of
operation. If the engine will be operated in very cold Proper grounding for the engine electrical system
conditions, then an extra cold starting aid may be is necessary for optimum engine performance
required. Normally, the engine will be equipped with and reliability. Improper grounding will result in
the correct type of starting aid for your region of uncontrolled electrical circuit paths and in unreliable
operation. electrical circuit paths.

The 800 Series engine is equipped with a glow plug Uncontrolled electrical circuit paths can result in
starting aid in each individual cylinder that heats the damage to main bearings, to crankshaft bearing
intake air in order to improve starting. journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frame

i01032808
ground straps can be damaged by electrical
Engine Stopping discharge.

To ensure that the engine and the engine electrical

systems function properly, an engine-to-frame ground
To avoid overheating of the engine and accelerated strap with a direct path to the battery must be used.
wear of the engine components, stop the engine This path may be provided by way of a direct engine
according to this Operation and Maintenance Manual, ground to the frame.
“Engine Stopping” topic (Operation Section).
All grounds should be tight and free of corrosion. The
Use the Emergency Stop Button (if equipped) engine alternator must be grounded to the negative
ONLY in an emergency situation. DO NOT use the “-” battery terminal with a wire that is adequate to
Emergency Stop Button for normal engine stopping. handle the full charging current of the alternator.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.

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

that has been serviced, make provisions to stop the
engine if an overspeed condition occurs. This may be
accomplished by shutting off the fuel supply and/or
the air supply to the engine.

i01940471

Electrical System

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible

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

Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. See
the Operation and Maintenance Manual for specific
starting instructions.
14
Product Information Section
Model Views

Product Information
Section

Model Views
i01933688

Model View Illustrations

g00988037
Illustration 8
 15
Product Information Section
Model Views

Left side view of naturally aspirated 800 Series engine

This view is shown without one of the fuel injection nozzles for clarity.
(1) Fan (6) Oil drain plug (11) Water drain plug
(2) Water pump (7) Relief valve (12) Lifting eye
(3) Oil filler (8) Oil filter (13) Oil filler cap
(4) Fuel injection pump (9) Flywheel housing (14) Glow plug
(5) Oil pressure switch (10) Oil level gauge (15) Fuel injection nozzle

g00988038
Illustration 9
Right side view of a naturally aspirated 800 Series engine
(15) Exhaust manifold (19) Alternator
(16) Starter (20) Thermostat
(17) Crankshaft vibration damper (21) Lifting eye
(18) V-Belt (22) Oil filler cap
16
Product Information Section
Model Views

g00987267
Illustration 10
Left side view of turbocharged 800 Series engine
(1) Oil cooler (9) Oil filter
(2) Fan (10) Flywheel housing
(3) Water pump (11) Water drain plug
(4) Oil filler (12) Oil level gauge
(5) Fuel injection pump (13) Crankcase breather
(6) Oil pressure switch (14) Inlet manifold
(7) Oil drain plug (15) Glow plug
(8) Relief valve (16) Fuel injection nozzle
 17
Product Information Section
Model Views

g00987270
Illustration 11
Right side view of turbocharged 800 Series engine
(17) Lifting eye (20) Crankshaft vibration damper (23) Thermostat
(18) Exhaust manifold (21) V-Belt (24) Lifting eye
(19) Starter (22) Alternator (25) Turbocharger
18
Product Information Section
Model Views

i01933689 • Oil cooler

Engine Description The engine lubricating oil is supplied by a gear
type pump. The engine lubricating oil is cooled and
the engine lubricating oil is filtered. Bypass valves
provide unrestricted flow of lubrication oil to the
Table 1
engine parts when oil viscosity is high. Bypass valves
Naturally Aspirated 800 Series Specifications can also provide unrestricted flow of lubrication oil
to the engine parts if the oil cooler should become
Type Four Stroke Cycle
plugged or if the oil filter element should become
Number of Cylinders 4 In-Line plugged.
Bore 94 mm (3.70 inch)
Engine efficiency, efficiency of emission controls, and
Stroke 120 mm (4.72 inch) engine performance depend on adherence to proper
operation and maintenance recommendations.
Aspiration Naturally Aspirated
Engine performance and efficiency also depend on
Compression ratio 22:1 the use of recommended fuels, lubrication oils, and
coolants. Refer to the Operation and Maintenance
Displacement 3.33 L (203 in3)
Manual, “Maintenance Interval Schedule” for more
Firing Order 1-3-4-2 information on maintenance items.
Rotation that is viewed
Counterclockwise
from the flywheel Engine Service Life
Valve Lash Setting (Inlet) 0.25 mm (0.0098 inch)
Engine efficiency and maximum utilization of engine
Valve Lash Setting performance depend on the adherence to proper
0.25 mm (0.0098 inch)
(Exhaust) operation and maintenance recommendations. In
addition, use recommended fuels, coolants and
Table 2 lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
Turbocharged 800 Series Specifications
Type Four Stroke Cycle Expected engine life is generally predicted by the
average power that is demanded. The average power
Number of Cylinders 4 In-Line that is demanded is based on fuel consumption of
Bore 94 mm (3.70 inch) the engine over a period of time. Reduced hours of
operation at full throttle and/or operating at reduced
Stroke 120 mm (4.72 inch) throttle settings result in a lower average power
Aspiration Turbocharged demand. Reduced hours of operation will increase
the length of operating time before an engine
Compression ratio 19:1 overhaul is required.
Displacement 3.33 L (203 in3)
Firing Order 1-3-4-2
Rotation that is viewed
Counterclockwise
from the flywheel
Valve Lash Setting (Inlet) 0.25 mm (0.0098 inch)
Valve Lash Setting
0.25 mm (0.0098 inch)
(Exhaust)

Engine Cooling and Lubrication

The cooling system consists of the following
components:

• Gear-driven centrifugal water pump

• Water temperature regulators which regulate the
engine coolant temperature

• Gear-driven oil pump (gear type)

 19
Product Information Section
Product Identification Information

Product Identification The Serial Number Plate is located on the left side of
the cylinder block.
Information
The following information is stamped on the Serial
Number Plate: Engine serial number, Model, and
i01933733 Arrangement number.
Engine Identification
i01892045

Reference Numbers
Perkins engines are identified by a serial number.
This number is shown on a serial number plate that
is mounted on the left hand side of the engine block.
Information for the following items may be needed to
An example of an engine number is UEU090001H. order parts. Locate the information for your engine.
Record the information on the appropriate space.
UE __________________________________________Type of engine Make a copy of this list for a record. Keep the
information for future reference.
U ____________________________Built in the United Kingdom
Record for Reference
0900001 _________________________Engine Serial Number
Engine Model _______________________________________________
H _____________________________________Year of Manufacture
Engine Serial No. __________________________________________
Perkins dealers need all of these numbers in order
to determine the components that were included with Engine Low Idle rpm ______________________________________
the engine. This permits accurate identification of
replacement part numbers. Engine Full Load rpm _____________________________________

i01933737 Primary Fuel Filter No. ____________________________________

Serial Number Plate Water Separator Element No. ___________________________

Secondary Fuel Filter Element No. ____________________

Lubrication Oil Filter Element No. ______________________

Auxiliary Oil Filter Element No. _________________________

Total Lubrication System Capacity _____________________

Total Cooling System Capacity _________________________

Air Cleaner Element No. _________________________________

Fan Drive Belt No. _________________________________________

Alternator Belt No. _________________________________________

i01933748

Emissions Certification Film

g00994966
Illustration 12 A typical example is shown.
Typical serial number plate
(1) Temporary Parts List number
(2) Type
(3) Serial number
(4) List number
20
Product Information Section
Product Identification Information

g01002325
Illustration 13
 21
Operation Section
Lifting and Storage

Operation Section i01942172

Engine Storage
Lifting and Storage
If the engine will not be started for several weeks, the
i01898037 lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
Engine Lifting walls. Rust on the cylinder walls will cause increased
engine wear and a reduction in engine service life.

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

Complete all of the lubrication recommendations that

are listed in this Operation and Maintenance Manual,
“Maintenance Interval Schedule” (Maintenance
Section).

If an engine is out of operation and if use of the engine

is not planned, special precautions should be made.
If the engine will be stored for more than one month,
a complete protection procedure is recommended.
g00103219
Illustration 14
Use the following guidelines :
NOTICE
Never bend the eyebolts and the brackets. Only load • Completely clean the outside of the engine.
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle • Drain the fuel system completely and refill
the system with preservative fuel.1772204
between the supporting members and the object be-
POWERPART Lay-Up 1 can be mixed with
comes less than 90 degrees.
the normal fuel in order to change the fuel into
preservative fuel.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight. • If preservative fuel is not available, the fuel system
can be filled with normal fuel. This fuel must be
discarded at the end of the storage period together
Use a hoist to remove heavy components. Use with the fuel filter elements.
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be • Operate the engine until the engine reaches
parallel to each other. The chains and cables should normal operating temperature. Stop any leaks from
be perpendicular to the top of the object that is being fuel, lubricating oil or air systems. Stop the engine
lifted. and drain the lubricating oil from the oil pan.

Some removals require lifting the fixtures in order to • Renew the canister(s) of the lubricating oil filter.
obtain proper balance and safety.
• Fill the oil pan to the Full Mark on the dipstick
To remove the engine ONLY, use the lifting eyes that with new, clean lubricating oil. Add 1762811
are on the engine. POWERPART Lay-Up 2 to the oil in order to
protect the engine against corrosion. If 1762811
Lifting eyes are designed and installed for specific POWERPART Lay-Up 2 is not available, use a
engine arrangements. Alterations to the lifting eyes preservative of the correct specification instead
and/or the engine make the lifting eyes and the lifting of the lubricating oil. If a preservative is used,
fixtures obsolete. If alterations are made, ensure this must be drained completely at the end of the
that proper lifting devices are provided. Consult your storage period and the oil pan must be refilled to
Perkins dealer for information regarding fixtures for the correct level with normal lubricating oil.
proper engine lifting.
22
Operation Section
Lifting and Storage

Cooling System Note: Certain corrosion inhibitors could cause

damage to some engine components. Contact the
To help prevent excessive engine wear, use the Service Department of Perkins for advice.
following guidelines:
8. Operate the engine for a short period in order to
NOTICE circulate the lubricating oil and the coolant in the
Do not drain the coolant while the engine is still hot and engine.
the system is under pressure because dangerous hot
coolant can be discharged. 9. Disconnect the battery. Put the battery into safe
storage in a fully charged condition. Before the
battery is put into storage, protect the terminals
If freezing temperatures are expected, check the against corrosion.1734115 POWERPART Lay-Up
cooling system for adequate protection against 3 can be used on the terminals.
freezing. See this Operation and Maintenance
Manual, “General Coolant Information” (Maintenance 10. Clean the crankcase breather if one is installed.
Section). Seal the end of the pipe.

11. Remove the fuel injector nozzles and spray

NOTICE
To prevent frost damage, ensure that all the coolant is 1762811 POWERPART Lay-Up 2 for one or two
seconds into each cylinder bore with the piston
removed from the engine. This is important if the sys-
at BDC.
tem is drained after it has been flushed with water, or if
an antifreeze solution too weak to protect the system
12. Slowly rotate the crankshaft for one complete
from frost has been used.
revolution and then replace the fuel injector
nozzles.

Induction System
• Remove the air filter assembly. If necessary,
remove the pipes that are installed between
the air filter assembly and the turbocharger.
Spray 1762811 POWERPART Lay-Up 2 into the
turbocharger. The duration of the spray is printed
on the container. Seal the turbocharger with
waterproof tape.

Exhaust System
g00987502
Illustration 15
• Remove the exhaust pipe. Spray 1762811
POWERPART Lay-Up 2 into the turbocharger. The
1. Ensure that the vehicle is on level ground. duration of the spray is printed on the container.
Seal the turbocharger with waterproof tape.
2. Remove the filler cap of the cooling system.

3. Remove the drain plug (1) from the side of the General Items
cylinder block in order to drain the engine. Ensure
that the drain hole is not restricted. • If the lubricating oil filler is installed on the rocker
cover, remove the filler cap. If the lubricating oil filler
4. Open the tap or remove the drain plug at the cap is not installed on the rocker cover, remove
bottom of the radiator in order to drain the radiator. the rocker cover. Spray 1762811 POWERPART
If the radiator does not have a tap or a drain plug, Lay-Up 2 around the rocker shaft assembly.
disconnect the hose at the bottom of the radiator. Replace the filler cap or the rocker cover.

5. Flush the cooling system with clean water. • Seal the vent of the fuel tank or the fuel filler cap
with waterproof tape.
6. Fit the drain plugs and the filler cap. Close the tap
or connect the radiator hose. • Remove the alternator drive belts and put the drive
belts into storage.
7. Fill the cooling system with an approved antifreeze
mixture because this gives protection against
corrosion.
 23
Operation Section
Lifting and Storage

• In order to prevent corrosion, spray the engine with

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

When the engine protection has been completed in

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

Your Perkins dealer or your Perkins distributor can

assist in preparing the engine for extended storage
periods.
24
Operation Section
Gauges and Indicators

Gauges and Indicators 1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

i01930356
3. Determine if the engine must be shut down
Gauges and Indicators immediately or if the engine can be cooled by
reducing the load.

Tachometer – This gauge indicates engine

Your engine may not have the same gauges or all of speed (rpm). When the throttle control lever
the gauges that are described. For more information is moved to the full throttle position without
about the gauge package, see the OEM information. load, the engine is running at high idle. The engine is
running at the full load rpm when the throttle control
Gauges provide indications of engine performance. lever is at the full throttle position with maximum
Ensure that the gauges are in good working order. rated load.
Determine the normal operating range by observing
the gauges over a period of time.
NOTICE
Noticeable changes in gauge readings indicate To help prevent engine damage, never exceed the
potential gauge or engine problems. Problems may high idle rpm. Overspeeding can result in serious
also be indicated by gauge readings that change damage to the engine. The engine can be operated
even if the readings are within specifications. at high idle without damage, but should never be
Determine and correct the cause of any significant allowed to exceed high idle rpm.
change in the readings. Consult your Perkins dealer
or your Perkins distributor for assistance. Ammeter – This gauge indicates the
amount of charge or discharge in the
NOTICE battery charging circuit. Operation of the
If no oil pressure is indicated, STOP the engine. If indicator should be to the right side of “0”(zero).
maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result. Fuel Level – This gauge indicates the fuel
level in the fuel tank. The fuel level gauge
Engine Oil Pressure – The oil pressure operates when the “START/STOP” switch
should be greatest after a cold engine is is in the “on” position.
started. The typical engine oil pressure with
SAE10W30 is 207 to 413 kPa (30 to 60 psi) at rated Service Hour Meter – The gauge indicates
rpm. operating time of the engine.

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

is stable and the gauge reading changes, perform
the following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature –

Typical temperature range is 71 to 96°C
(160 to 205°F). The maximum allowable
temperature with the pressurized cooling system at
48 kPa (7 psi) is 110°C (230°F). Higher temperatures
may occur under certain conditions. The water
temperature reading may vary according to load. The
reading should never exceed the boiling point for the
pressurized system that is being used.

If the engine is operating above the normal range

and steam becomes apparent, perform the following
procedure:
 25
Operation Section
Engine Starting

Engine Starting • Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
i01903008 to the controls.

Before Starting Engine • Ensure that the areas around the rotating parts are
clear.

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

Before the engine is started, perform the required damaged guards or for missing guards. Repair
daily maintenance and any other periodic any damaged guards. Replace damaged guards
maintenance that is due. Refer to the Operation and/or missing guards.
and Maintenance Manual, “Maintenance Interval
Schedule” for more information. • Disconnect any battery chargers that are not
protected against the high current drain that
• For the maximum service life of the engine, make a is created when the electric starting motor is
thorough inspection within the engine compartment engaged. Check electrical cables and check the
before the engine is started. Look for the following battery for poor connections and for corrosion.
items: oil leaks, coolant leaks, loose bolts, and
excessive dirt and/or grease. Remove any excess • Reset all of the shutoffs or alarm components (if
dirt and/or grease buildup. Repair any faults that equipped).
were identified during the inspection.
• Check the engine lubrication oil level. Maintain the
• Inspect the cooling system hoses for cracks and oil level between the “ADD” mark and the “FULL”
for loose clamps. mark on the oil level dipstick.

• Inspect the alternator and accessory drive belts for • Check the coolant level. Observe the coolant level
cracks, breaks, and other damage. in the header tank (if equipped). Maintain the
coolant level to the “FULL” mark on the header
• Inspect the wiring for loose connections and for tank.
worn wires or frayed wires.
• If the engine is not equipped with a header tank
• Check the fuel supply. Drain water from the water maintain the coolant level within 13 mm (0.5 inch)
separator (if equipped). Open the fuel supply valve of the bottom of the filler pipe. If the engine is
(if equipped). equipped with a sight glass, maintain the coolant
level in the sight glass.
NOTICE
All valves in the fuel return line must be open before • Observe the air cleaner service indicator (if
and during engine operation to help prevent high fuel equipped). Service the air cleaner when the yellow
pressure. High fuel pressure may cause filter housing diaphragm enters the red zone, or when the red
failure or other damage. piston locks in the visible position.

• Ensure that any equipment that is driven by the

If the engine has not been started for several weeks, engine has been disengaged from the engine.
fuel may have drained from the fuel system. Air Minimize electrical loads or remove any electrical
may have entered the filter housing. Also, when fuel loads.
filters have been changed, some air pockets will be
trapped in the engine. In these instances, prime the
fuel system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system.

Engine exhaust contains products of combustion

which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
26
Operation Section
Engine Starting

i01934161 i01929012

Starting the Engine Starting with Jump Start

Cables

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury. Improper jump start cable connections can cause
an explosion resulting in personal injury.

NOTICE Prevent sparks near the batteries. Sparks could

Do not crank the engine for more than 10 seconds. cause vapors to explode. Do not allow jump start
Allow the starter motor to cool for 30 seconds before cable ends to contact each other or the engine.
cranking again. Do not engage the starter when the
flywheel is turning. Note: If it is possible, first diagnose the reason
for the starting failure. Make any necessary
Refer to the “OEM Manual” for your type of controls. repairs. If the engine will not start only due to
the condition of the battery, either charge the
1. Remove any load from the engine. Disengage any battery, or start the engine with jump start cables.
driven equipment. The condition of the battery can be rechecked
after the engine has been switched OFF.
2. Crank the engine. Start the engine.

3. If the engine does not start, release the engine NOTICE

start switch and allow the electric starting motor Using a battery source with the same voltage as the
to cool. electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
4. If the ambient temperature is low, activate the the electrical system.
glow plugs according to Table 3.
Do not reverse the battery cables. The alternator can
Table 3 be damaged. Attach ground cable last and remove
Preheat Times first.
Temperature Preheat Time When using an external electrical source to start the
5 °C (41 °F) 10 seconds engine, turn the generator set control switch to the
“OFF” position. Turn all electrical accessories OFF be-
−5 °C (23 °F) to 4 °C (40 °F) 20 seconds fore attaching the jump start cables.
Less than −5 °C (23 °F) 30 seconds
Ensure that the main power switch is in the OFF posi-
Continuous Preheat 60 seconds maximum tion before attaching the jump start cables to the en-
gine being started.
5. Crank the engine. Start the engine.
1. Turn the start switch to the OFF position. Turn off
6. Allow the engine to idle for 5 to 10 minutes before all the engine’s accessories.
applying a load to the engine. Check the oil
pressure gauge. The oil pressure gauge should 2. Connect one positive end of the jump start cable
be at the proper value. to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
electrical source.
 27
Operation Section
Engine Starting

3. Connect one negative end of the jump start cable

to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting the combustible
gases that are produced by some batteries.

4. Start the engine.

5. Immediately after the stalled engine is started,

disconnect the jump start cables in reverse order.

After jump starting, the alternator may not be able to

fully recharge batteries that are severely discharged.
The batteries must be replaced or charged to the
proper voltage with a battery charger after the engine
is stopped. Many batteries which are considered
unusable are still rechargeable. Refer to Operation
and Maintenance Manual, “Battery - Replace” and
Testing and Adjusting Manual, “Battery - Test”.

i01903609

After Starting Engine

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

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

When the engine idles during warm-up, observe the

following conditions:

• Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
possible in some applications.

• Operate the engine at low idle until all systems

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

Note: Gauge readings should be observed and

the data should be recorded frequently while the
engine is operating. Comparing the data over time
will help to determine normal readings for each
gauge. Comparing data over time will also help
detect abnormal operating developments. Significant
changes in the readings should be investigated.
28
Operation Section
Engine Operation

Engine Operation i01934633

Fuel Conservation Practices

i01903587

Engine Operation
The efficiency of the engine can affect the fuel
economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
Proper operation and maintenance are key factors all applications. Follow the recommended procedures
in obtaining the maximum life and economy of in order to attain optimum performance for the life
the engine. If the directions in the Operation and of the engine.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. • Avoid spilling fuel.
The engine can be operated at the rated rpm after the Fuel expands when the fuel is warmed up. The fuel
engine reaches operating temperature. The engine may overflow from the fuel tank. Inspect fuel lines for
will reach normal operating temperature sooner leaks. Repair the fuel lines, as needed.
during a low engine speed (rpm) and during a low
power demand. This procedure is more effective than • Be aware of the properties of the different fuels.
idling the engine at no load. The engine should reach Use only the recommended fuels.
operating temperature in a few minutes.
• Avoid unnecessary idling.
Gauge readings should be observed and the data
should be recorded frequently while the engine Shut off the engine rather than idle for long periods of
is operating. Comparing the data over time will time.
help to determine normal readings for each gauge.
Comparing data over time will also help detect • Observe the service indicator frequently. Keep the
abnormal operating developments. Significant air cleaner elements clean.
changes in the readings should be investigated.
• Maintain a good electrical system.
One damaged battery cell will overwork the alternator.
This will consume excess power and excess fuel.

• Ensure that the belts are properly adjusted. The

belts should be in good condition.

• Ensure that all of the connections of the hoses are

tight. The connections should not leak.

• Ensure that the driven equipment is in good

working order.

• Cold engines consume excess fuel. Utilize heat

from the jacket water system and the exhaust
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without water temperature regulators.
All of these items will help maintain operating
temperatures.
 29
Operation Section
Engine Stopping

Engine Stopping i01935215

After Stopping Engine

i01935195

Stopping the Engine

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
Stopping the engine immediately after it has been • Check the crankcase oil level. Maintain the oil level
working under load, can result in overheating and ac- between the “MIN” mark and the “MAX” mark on
celerated wear of the engine components. the oil level dipstick.

Avoid accelerating the engine prior to shutting it down. • If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.
Avoiding hot engine shutdowns will maximize tur-
bocharger shaft and bearing life. • If the engine is equipped with a service hour meter,
note the reading. Perform the maintenance that
is in the Operation and Maintenance Manual,
Note: Individual applications will have different “Maintenance Interval Schedule”.
control systems. Ensure that the shutoff procedures
are understood. Use the following general guidelines • Fill the fuel tank in order to help prevent
in order to stop the engine. accumulation of moisture in the fuel. Do not overfill
the fuel tank.
1. Remove the load from the engine. Reduce the
engine speed (rpm) to low idle. Perform this NOTICE
procedure for five to six minutes in order to cool Only use antifreeze/coolant mixtures recommended in
the engine. the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause
2. Stop the engine after the cool down period engine damage.
according to the shutoff system on the engine and
turn the ignition key switch to the OFF position.
If necessary, refer to the instructions that are • Allow the engine to cool. Check the coolant level.
provided by the OEM.
• If freezing temperatures are expected, check
the coolant for proper antifreeze protection. The
i01903586 cooling system must be protected against freezing
to the lowest expected outside temperature. Add
Emergency Stopping the correct coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
NOTICE the instructions from the OEM.
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.

The OEM may have equipped the application with

an emergency stop button. For more information
about the emergency stop button, refer to the OEM
information.

Ensure that any components for the external system

that support the engine operation are secured after
the engine is stopped.
30
Operation Section
Cold Weather Operation

Cold Weather Operation • Install the correct lubricant in each compartment

before the beginning of cold weather.

i01903584 • Check all rubber parts (hoses, fan drive belts, etc)
weekly.
Cold Weather Operation
• Check all electrical wiring and connections for any
fraying or damaged insulation.
Perkins Diesel Engines can operate effectively in • Keep all batteries fully charged and warm.
cold weather. During cold weather, the starting and
the operation of the diesel engine is dependent on • Fill the fuel tank at the end of each shift.
the following items:
• Check the air cleaners and the air intake daily.
• The type of fuel that is used Check the air intake more often when you operate
in snow.
• The viscosity of the oil
• The operation of the air inlet heater starting aid
Personal injury or property damage can result
• Optional Cold starting aid from alcohol or starting fluids.
The purpose of this section will cover the following
information: Alcohol or starting fluids are highly flammable and
toxic and if improperly stored could result in injury
or property damage.
• Explain potential problems that are caused by cold
weather operation.

• Suggest steps which can be taken in order to

minimize starting problems and operating problems
when the ambient air temperature is colder than Do not use aerosol types of starting aids such as
0 to −55 °C (32 to −67 °F). ether. Such use could result in an explosion and
personal injury.
The operation and maintenance of an engine in
freezing temperatures is complex. This is because • For jump starting with cables in cold weather,
of the following conditions: the unlimited differences refer to the Operation and Maintenance Manual,
in weather conditions, engine applications, and “Starting with Jump Start Cables.” for instructions.
the supplies that are available in your area. These
factors and recommendations from your Perkins
dealer are based on past proven practices. The Viscosity of the Engine Lubrication
information that is contained in this section should Oil
be combined in order to provide guidelines for cold
weather operations. Proper engine oil viscosity is essential. Oil viscosity
affects the amount of torque that is needed to
Hints for Cold Weather Operation crank the engine. Refer to the Operation and
Maintenance Manual, “Lubricant Specifications” for
the recommended viscosity of oil.
• If the engine will start, operate the engine until a
minimum operating temperature of 71 °C (160 °F)
is achieved. Achieving operating temperature will Recommendations for the Coolant
help prevent the intake valves and exhaust valves
from sticking. Provide cooling system protection for the lowest
expected outside temperature. Refer to the Operation
• The cooling system and the lubrication system and Maintenance Manual, “General Coolant
for the engine do not lose heat immediately upon Information” for the recommended coolant mixture.
shutdown. This means that an engine can be shut
down for a few hours and the engine can still have In cold weather, check the coolant often for the proper
the ability to start readily. If the engine is shut glycol concentration in order to ensure adequate
down for at least eight hours, the engine should be freeze protection.
considered cooled to outside temperature.
 31
Operation Section
Cold Weather Operation

Engine Block Heaters • Pushrods are bent.

Engine block heaters (if equipped) heat the • Other damage to valve train components can
engine jacket water that surrounds the combustion result.
chambers. This provides the following functions:
For this reason, when the engine is started,
• Startability is improved. the engine must be operated until the coolant
temperature is 71 °C (160 °F) minimum. Carbon
• Warm up time is reduced. deposits on the valve stems will be kept at a minimum
and the free operation of the valves and the valve
An electric block heater can be activated once components will be maintained.
the engine is stopped. An effective block heater
is typically a 1250/1500 W unit. Consult your In addition, the engine must be thoroughly warmed in
Perkins dealer or your Perkins distributor for more order to keep other engine parts in better condition
information. and the service life of the engine will be generally
extended. Lubrication will be improved. There will be
less acid and less sludge in the oil. This will provide
Idling the Engine longer service life for the engine bearings, the piston
When idling after the engine is started in cold rings, and other parts. However, limit unnecessary
idle time to ten minutes in order to reduce wear and
weather, increase the engine rpm from 1000 to 1200
unnecessary fuel consumption.
rpm. This will warm up the engine more quickly.
Maintaining an elevated low idle speed for extended
periods will be easier with the installation of a hand Purge Valve and Insulated Heater Lines
throttle. The engine should not be “raced” in order to
speed up the warm up process. The engine is equipped with a water temperature
regulator in order to allow the engine to reach the
While the engine is idling, the application of a light correct operating temperature quickly. The water
load (parasitic load) will assist in maintaining the temperature regulator remains in the closed position
minimum operating temperature. The minimum until the jacket water coolant temperature has
operating temperature is 71 °C (160 °F). reached the engine’s operating temperature. The
jacket water circulates from the top of the cylinder
block, to the water temperature regulator housing,
Recommendations for Coolant and back to the bottom of the cylinder block via the
Warm Up bypass. The water temperature regulator allows
some flow of water and/or air to pass through the
Warm up an engine that has cooled below normal water temperature regulator in order to ensure a
operating temperatures due to inactivity. This should continuous flow of coolant within the cylinder block.
be performed before the engine is returned to full This is achieved via a small “jiggle” valve in the
operation. During operation in very cold temperature water temperature regulator. The water temperature
conditions, damage to engine valve mechanisms can regulator moves to the open position when the jacket
result from engine operation for short intervals. This water coolant temperature has reached the correct
can happen if the engine is started and the engine is operating temperature. The water temperature
stopped many times without being operated in order regulator moves to the open position in order to allow
to warm up completely. the passage of the coolant through the radiator to
dissipate excess heat.
When the engine is operated below normal operating
temperatures, fuel and oil are not completely burned The above procedure is good for normal engine
in the combustion chamber. This fuel and oil causes operating conditions in temperate climates. During
soft carbon deposits to form on the valve stems. periods of operations in a cold climate with a light
Generally, the deposits do not cause problems and engine load, the coolant must bypass the radiator in
the deposits are burned off during operation at order to help prevent excessive cooling of the engine.
normal engine operating temperatures. Coolant that passes through the radiator must be
minimized in order to maintain the engine operating
When the engine is started and the engine is stopped temperature in cold weather.
many times without being operated in order to warm
up completely, the carbon deposits become thicker. Excessive cooling of the engine can be prevented
This will cause the following problems: by a valve that allows unnecessary coolant flow to
be diverted from the water temperature regulator
• Free operation of the valves is prevented. and back to the bottom of the engine block without
passing through the radiator.
• Valves become stuck.
32
Operation Section
Cold Weather Operation

Note: Perkins discourages the use of all airflow Group 1 fuels are the preferred Group of Fuels for
restriction devices such as radiator shutters. general use by Perkins. Group 1 fuels maximize
Restriction of the airflow can result in the following: engine life and engine performance. Group 1 fuels
high exhaust temperatures, power loss, excessive are usually less available than Group 2 fuels.
fan usage, and reduction in fuel economy. Frequently, Group 1 fuels are not available in colder
climates during the winter.
Cab heater lines for very cold weather are also
beneficial. These lines provide more available heat Note: Group 2 fuels must have a maximum wear
from the coolant to the cab. The feed from the engine scar of 650 micrometers (HFRR to ISO 12156-1).
and the return lines from the cab should be insulated
in order to reduce heat loss to the outside air. Group 2 fuels are considered acceptable for issues
of warranty. This group of fuels may reduce the life
Insulating the Air Inlet and Engine of the engine, the engine’s maximum power, and the
engine’s fuel efficiency.
Compartment
When Group 2 diesel fuels are used the following
When temperatures below −18 °C (−0 °F) will be components provide a means of minimizing problems
frequently encountered, an air cleaner inlet that
in cold weather:
is located in the engine compartment may be
specified. An air cleaner that is located in the engine
compartment may also minimize the entry of snow • Glow plugs, which are standard equipment on all
800 Series engines
into the air cleaner. Also, heat that is rejected by the
engine helps to warm the intake air.
• Engine coolant heaters, which may be an OEM
option
Additional heat can be retained around the engine by
insulating the engine compartment.
• Fuel heaters, which may be an OEM option
i01935225 • Fuel line insulation, which may be an OEM option
Fuel and the Effect from Cold There are three major differences between Group
Weather 1 fuels and Group 2 fuels. Group 1 fuels have the
following different characteristics to Group 2 fuels.

• A lower cloud point

Note: Only use grades of fuel that are recommended
by Perkins. Refer to this Operation and Maintenance • A lower pour point
Manual, “Fuel Recommendations”.
• A higher rating of kJ (BTU) per unit volume of fuel
The following fuels can be used for the Perkins 800
The cloud point is the temperature when a cloud of
Series engine.
wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is
• Group 1 the temperature when diesel fuel will thicken. The
diesel fuel becomes more resistant to flow through
• Group 2 fuel pumps and through the fuel lines.
• Group 3 Be aware of these values when diesel fuel is
purchased. Consider the average ambient air
• Special Fuels temperature for the engine’s application. Engines
that are fueled in one climate may not operate well if
Perkins prefer only Group 1 and Group 2 fuels for
the engines are moved to another climate. Problems
use in 800 Series engines. Group 3 fuels include Low
can result due to changes in temperature.
Temperature Fuels and Aviation Kerosene Fuels.
Before troubleshooting for low power or for poor
Note: Group 3 fuels reduce the life of the engine. The
performance in the winter, check the type of fuel that
use of Group 3 fuels is not covered by the Perkins
is being used.
warranty.

Special fuels include Biofuel.

 33
Operation Section
Cold Weather Operation

Low temperature fuels may be available for engine i01903588

operation at temperatures below 0 °C (32 °F). These
fuels limit the formation of wax in the fuel at low Fuel Related Components in
temperatures. Wax in the fuel may prevent the flow
of the fuel through the fuel filters.
Cold Weather
For more information on cold weather operation, see
Operation and Maintenance Manual, “Cold Weather
Operation and Fuel Related Components in Cold Fuel Tanks
Weather”.
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for draining

water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.

Some fuel tanks use supply lines that take fuel

directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.

Drain the water and sediment from any fuel storage

tank at the following intervals: weekly, oil changes,
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.

Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more
information on priming the fuel system.

The micron rating and the location of a primary fuel

filter is important in cold weather operation. The
primary fuel filter and the fuel supply line are the most
common components that are affected by cold fuel.

Fuel Heaters
Note: The OEM may equip the application with fuel
heaters. If this is the case, disconnect an electric type
of fuel heater in warm weather in order to prevent
overheating of the fuel. If the type of fuel heater is a
heat exchanger, the OEM should have included a
bypass for warm weather. Ensure that the bypass is
operational during warm weather in order to prevent
overheating of the fuel.

For more information about fuel heaters (if equipped),

refer to the OEM information.
34
Maintenance Section
Lubricant Specifications

Maintenance Section Table 4

API Classifications
Current Obsolete
Lubricant Specifications CF-4, CG-4, CH-4 CE
CF CC, CD
i01903582
CF-2(1) CD-2(1)
Lubricant Information (1) The classifications CD-2 and American Petroleum Institute
CF-2 are for two-cycle diesel engines. Perkins does not sell
engines that utilize CD-2 and API CF-2 oils.

General Information Terminology

Because of government regulations regarding Certain abbreviations follow the nomenclature of

the certification of engine exhaust emissions, the “SAE J754”. Some classifications follow “SAE J183”
lubricant recommendations must be followed. abbreviations, and some classifications follow the
“EMA Recommended Guideline on Diesel Engine
Oil”. In addition to Perkins definitions, there are other
Engine Manufacturers Association definitions that will be of assistance in purchasing
(EMA) Oils lubricants. Recommended oil viscosities can be found
in this publication, “Engine Oil” topic (Maintenance
The “Engine Manufacturers Association Section).
Recommended Guideline on Diesel Engine Oil” is
recognized by Perkins. For detailed information i01903583
about this guideline, see the latest edition of EMA
publication, “EMA DHD -1”. Engine Oil
API Oils
The Engine Oil Licensing and Certification System by Commercial Oils
the American Petroleum Institute (API) is recognized
by Perkins. For detailed information about this The performance of commercial diesel engine
system, see the latest edition of the “API publication oils is based on American Petroleum Institute
No. 1509”. Engine oils that bear the API symbol are (API) classifications. These API classifications are
authorized by API. developed in order to provide commercial lubricants
for a broad range of diesel engines that operate at
various conditions.

Only use commercial oils that meet the following

classifications:

• EMA DHD-1 multigrade oil (preferred oil)

• API CH-4 multigrade oil (preferred oil)
• ACEAE3
In order to make the proper choice of a commercial
oil, refer to the following explanations:
g00546535
Illustration 16
Typical API symbol

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

not been API authorized classifications since 1
January 1996. Table 4 summarizes the status of the
classifications.
 35
Maintenance Section
Lubricant Specifications

EMA DHD-1 – The Engine Manufacturers Three new engine tests were developed for the API
Association (EMA) has developed lubricant CH-4 oil. The first test specifically evaluates deposits
recommendations as an alternative to the API oil on pistons for engines with the two-piece steel piston.
classification system. DHD-1 is a Recommended This test (piston deposit) also measures the control
Guideline that defines a level of oil performance for of oil consumption. A second test is conducted
these types of diesel engines: high speed, four stroke with moderate oil soot. The second test measures
cycle, heavy-duty, and light duty. DHD-1 oils may the following criteria: wear of piston rings, wear of
be used in Perkins engines when the following oils cylinder liners, and resistance to corrosion. A third
are recommended: API CH-4, API CG-4, and API new test measures the following characteristics with
CF-4. DHD-1 oils are intended to provide superior high levels of soot in the oil: wear of the valve train,
performance in comparison to API CG-4 and API resistance of the oil in plugging the oil filter, and
CF-4. control of sludge.

DHD-1 oils will meet the needs of high performance In addition to the new tests, API CH-4 oils have
Perkins diesel engines that are operating in many tougher limits for viscosity control in applications that
applications. The tests and the test limits that are generate high soot. The oils also have improved
used to define DHD-1 are similar to the new API oxidation resistance. API CH-4 oils must pass an
CH-4 classification. Therefore, these oils will also additional test (piston deposit) for engines that use
meet the requirements of the low emissions diesel aluminum pistons (single piece). Oil performance is
engines. DHD-1 oils are designed to control the also established for engines that operate in areas
harmful effects of soot with improved wear resistance with high sulfur diesel fuel.
and improved resistance to plugging of the oil filter.
These oils will also provide superior piston deposit All of these improvements allow the API CH-4
control for engines with either two-piece steel pistons oil to achieve optimum oil change intervals. API
or aluminum pistons. CH-4 oils are recommended for use in extended oil
change intervals. API CH-4 oils are recommended
All DHD-1 oils must complete a full test program for conditions that demand a premium oil. Your
with the base stock and with the viscosity grade of Perkins dealer or your Perkins distributor has specific
the finished commercial oil. The use of “API Base guidelines for optimizing oil change intervals.
Oil Interchange Guidelines” are not appropriate for
DHD-1 oils. This feature reduces the variation in Some commercial oils that meet the API
performance that can occur when base stocks are classifications may require reduced oil change
changed in commercial oil formulations. intervals. To determine the oil change interval, closely
monitor the condition of the oil and perform a wear
DHD-1 oils are recommended for use in extended metal analysis.
oil change interval programs that optimize oil life.
These oil change interval programs are based on oil NOTICE
analysis. DHD-1 oils are recommended for conditions Failure to follow these oil recommendations can cause
that demand a premium oil. Your Perkins dealer or shortened engine service life due to deposits and/or
your Perkins distributor has the specific guidelines excessive wear.
for optimizing oil change intervals.

API CH-4 – API CH-4 oils were developed in order to Total Base Number (TBN) and Fuel
meet the requirements of the new high performance
diesel engines. Also, the oil was designed to Sulfur Levels for Direct Injection
meet the requirements of the low emissions diesel (DI) Diesel Engines
engines. API CH-4 oils are also acceptable for use
in older diesel engines and in diesel engines that The Total Base Number (TBN) for an oil depends on
use high sulfur diesel fuel. API CH-4 oils may be the fuel sulfur level. For direct injection engines that
used in Perkins engines that use API CG-4 and API use distillate fuel, the minimum TBN of the new oil
CF-4 oils. API CH-4 oils will generally exceed the must be 10 times the fuel sulfur level. The TBN is
performance of API CG-4 oils in the following criteria: defined by “ASTM D2896”. The minimum TBN of the
deposits on pistons, control of oil consumption, wear oil is 5 regardless of fuel sulfur level. Illustration 17
of piston rings, valve train wear, viscosity control, demonstrates the TBN.
and corrosion.
36
Maintenance Section
Lubricant Specifications

Refer to Table 6 (minimum temperature) in order to

determine the required oil viscosity for starting a cold
engine.

Refer to Table 6 (maximum temperature) in order to

select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that is

available to meet the requirement for the temperature
at start-up.

Table 6
Engine Oil Viscosity
g00799818
Illustration 17 EMA LRG-1 Ambient Temperature
(Y) TBN by “ASTM D2896” API CH-4
(X) Percentage of fuel sulfur by weight Viscosity Grade Minimum Maximum
(1) TBN of new oil
(2) Change the oil when the TBN deteriorates to 50 percent of SAE 0W20 −40 °C (−40 °F) 10 °C (50 °F)
the original TBN.
SAE 0W30 −40 °C (−40 °F) 30 °C (86 °F)
Use the following guidelines for fuel sulfur levels that SAE 0W40 −40 °C (−40 °F) 40 °C (104 °F)
exceed 1.5 percent:
SAE 5W30 −30 °C (−22 °F) 30 °C (86 °F)
• Choose an oil with the highest TBN that meets one SAE 5W40 −30 °C (−22 °F) 40 °C (104 °F)
of these classifications: EMA DHD-1 and API CH-4.
SAE 10W30 −20 °C (−4 °F) 40 °C (104 °F)
• Reduce the oil change interval. Base the oil SAE 15W40 −10 °C (14 °F) 50 °C (122 °F)
change interval on the oil analysis. Ensure that the
oil analysis includes the condition of the oil and
a wear metal analysis. i01903738

Excessive piston deposits can be produced by an oil Synthetic Base Stock Oils
with a high TBN. These deposits can lead to a loss
of control of the oil consumption and to the polishing
of the cylinder bore.
Synthetic base oils are acceptable for use in
these engines if these oils meet the performance
NOTICE requirements that are specified for the engine.
Operating Direct Injection (DI) diesel engines with fuel
sulphur levels over 0.5 percent will require shortened Synthetic base oils generally perform better than
oil change intervals in order to help maintain adequate conventional oils in the following two areas:
wear protection.
• Synthetic base oils have improved flow at low
Table 5 temperatures especially in arctic conditions.
Percentage of Sulfur in the Oil change interval
fuel • Synthetic base oils have improved oxidation
stability especially at high operating temperatures.
Lower than 0.5 Normal
0.5 to 1.0 0.75 of normal Some synthetic base oils have performance
characteristics that enhance the service life of the
Greater than 1.0 0.50 of normal oil. Perkins does not recommend the automatic
extending of the oil change intervals for any type of
oil.
Lubricant Viscosity Recommendations
for Direct Injection (DI) Diesel Engines
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during
cold engine start-up, and the maximum ambient
temperature during engine operation.
 37
Maintenance Section
Lubricant Specifications

i01903742
NOTICE
Re-refined Base Stock Oils Shortened engine service life could result if second
choice oils are used.

Re-refined base stock oils are acceptable for

i01904027
use in Perkins engines if these oils meet the
performance requirements that are specified by Aftermarket Oil Additives
Perkins. Re-refined base stock oils can be used
exclusively in finished oil or in a combination with
new base stock oils. The US military specifications
and the specifications of other heavy equipment Perkins does not recommend the use of aftermarket
manufacturers also allow the use of re-refined base additives in oil. It is not necessary to use aftermarket
stock oils that meet the same criteria. additives in order to achieve the engine’s maximum
service life or rated performance. Fully formulated,
The process that is used to make re-refined base finished oils consist of base oils and of commercial
stock oil should adequately remove all wear metals additive packages. These additive packages are
that are in the used oil and all the additives that blended into the base oils at precise percentages in
are in the used oil. The process that is used to order to help provide finished oils with performance
make re-refined base stock oil generally involves the characteristics that meet industry standards.
process of vacuum distillation and hydrotreating the
used oil. Filtering is adequate for the production of There are no industry standard tests that evaluate
high quality, re-refined base stock oil. the performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may
i01903752
not be compatible with the finished oil’s additive
package, which could lower the performance of the
Cold Weather Lubricants finished oil. The aftermarket additive could fail to
mix with the finished oil. This could produce sludge
in the crankcase. Perkins discourages the use of
aftermarket additives in finished oils.
When an engine is started and an engine is operated
in ambient temperatures below −20 °C (−4 °F), use To achieve the best performance from a Perkins
multigrade oils that are capable of flowing in low engine, conform to the following guidelines:
temperatures.
• Select the proper oil, or a commercial oil that meets
These oils have lubricant viscosity grades of SAE the “EMA Recommended Guideline on Diesel
0W or SAE 5W. Engine Oil” or the recommended API classification.

When an engine is started and operated in ambient • See the appropriate “Lubricant Viscosities” table in
temperatures below −30 °C (−22 °F), use a synthetic order to find the correct oil viscosity grade for your
base stock multigrade oil with a 0W viscosity grade engine.
or with a 5W viscosity grade. Use an oil with a pour
point that is lower than −50 °C (−58 °F). • At the specified interval, service the engine. Use
new oil and install a new oil filter.
The number of acceptable lubricants is limited in
cold weather conditions. Perkins recommends the • Perform maintenance at the intervals that are
following lubricants for use in cold weather conditions: specified in the Operation and Maintenance
Manual, “Maintenance Interval Schedule”.
First Choice – Use oil with an EMA DHD-1
Recommended Guideline. Use a CH-4 oil that has
an API license. The oil should be either SAE 0W20,
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
lubricant viscosity grade.

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

additive package. Although the oil has not been
tested for the requirements of the API license, the oil
must be either SAE 0W20, SAE 0W30, SAE 0W40,
SAE 5W30, or SAE 5W40.
38
Maintenance Section
Fuel Specifications

Fuel Specifications Diesel engines have the ability to burn a wide variety
of fuels. These fuels are divided into four general
groups:
i01904061
• Group 1 (preferred fuels)
Fuel Recommendations
• Group 2 (permissible fuels)
• Group 3 (aviation kerosene fuels)
To get the correct power and performance from
the engine, use a fuel of the correct quality. The • Other fuels
recommended fuel specification for the Perkins 1106
engine is shown below: Group 1 (preferred fuels): Specification

• Cetane number___________________________45 minimum “DERV to EN590”

• Viscosity___________ 2,0 to 4.5 cSt at 40 °C (104 °F) Note: Only use Arctic fuels when the temperature is
below 0 °C (32 °F). Do not use Arctic fuels when the
• Density________________________0.835 to 0.855 Kg/liter ambient temperature is above 0 °C (32 °F). To ensure
that the time period between cranking the engine and
• Sulfur_______________________0.2% of mass, maximum first fire is kept to a minimum, only use fuel of the
correct viscosity and at the correct temperature.
• Distillation___________________85% at 350 °C (662 °F)
Gas oil to “BS2869 Class A2”
• Lubricity______________________________460 micrometers
maximum wear scar on “ISO 12156 - 1” “ASTM D975 - 91 Class 2D” This can only be used if
the fuel has the correct specification of lubricity.
Cetane number
“JIS K2204 (1992) Grades 1,2,3 and Special Grade
This indicates the properties of ignition of the fuel. 3” This can only be used if the fuel has the correct
Fuel with a low cetane number can be the root specification of lubricity.
cause of problems during cold start. This will affect
combustion. Note: If low sulfur or low sulfur aromatic fuels are
used, then fuel additives can be used to increase
Viscosity lubricity.
This is the resistance to flow of a fluid. If this Group 2 (permissible fuels): Specification
resistance is outside the limits, the engine and the
engine starting performance in particular can be These fuel specifications are considered acceptable
affected. for issues of warranty. However,these fuels may
reduce the life of the engine, the engine’s maximum
Sulfur power and the engine’s fuel efficiency.
High sulfur content of the fuel is not normally found “ASTM D975 - 91 Class 1D”
in Europe, North America or Australasia. This can
cause engine wear. When only high sulfur fuels “JP7, Mil T38219”
are available, it will be necessary that high alkaline
lubricating oil is used in the engine or that the “NATO F63”
lubricating oil change interval is reduced.
NOTICE
Distillation These fuels should have a wear scar value of 650
micrometers maximum “HFRR to ISO 12156 - 1” and
This is an indication of the mixture of different can only be used on VP30 24 volt specifications.
hydrocarbons in the fuel. A high ratio of light weight
hydrocarbons can affect the characteristics of
combustion. Group 3 (aviation kerosene fuels): Specification

Lubricity These fuels need additives to achieve lubricity of 650

micrometers wear scar and the reliability of the fuel
This is the capability of the fuel to prevent pump wear. injection pump will be reduced. The fuel injection
pump is not covered by a warranty, even when the
additives are included.
 39
Maintenance Section
Fuel Specifications

“JP5 MIL T5624 (Avcat FSII, NATO F44” Table 7

Perkins Specifications for Distillate Diesel Fuel
“JP8 T83133 (Avtur FSII, NATO F34”
Specifications Requirements ASTM Test
“Jet A” Aromatics 35% maximum “D1319”
“Jet A1, NATO F35, XF63” Ash 0.02% maximum
“D482”
(weight)
Low temperature fuels Carbon Residue 0.35% maximum
“D524”
on 10% Bottoms (weight)
Special fuels for use in cold weather may be available
for engine operation at temperatures below 0 °C Cetane Number 40 minimum (DI
engines) “D613”
(32 °F). These fuels limit the formation of wax in the
fuel oil at low temperatures. If wax forms in the fuel
Cloud Point The cloud
oil, this could stop the flow of fuel oil through the filter. point must not
exceed the -
Note: These fuels that lack lubricity may cause the lowest expected
following problems: ambient
temperature.
• Low engine power Copper Strip No. 3 maximum
“D130”
Corrosion
• Difficult starting in hot conditions or in cold
conditions Distillation 10% at 282 °C
(540 °F)
• White smoke maximum
“D86”
90% at 360 °C
• Deterioration of emissions and misfire at certain (680 °F)
operating conditions maximum

Biofuel: Specification Flash Point legal limit “D93”

API Gravity 30 minimum
Biofuel: A 5% mix of RME to EN14214 in conventional “D287”
fuel is permitted. 45 maximum
Pour Point 6 °C (10 °F)
NOTICE minimum
“D97”
Water emulsion fuels: These fuels are not permitted below ambient
temperature
Sulfur (1) 0.2% maximum “D3605”
Refer to the following fuel specifications for or
North America. “D1552”

The preferred fuels provide maximum engine service Kinematic 2.0 cSt minimum
life and performance. The preferred fuels are distillate Viscosity (2) and 4.5 cSt
“D445”
fuels. These fuels are commonly called diesel fuel maximum at
40 °C (104 °F)
or gas oil.
Water and 0.1% maximum
“D1796”
The permissible fuels are crude oils or blended fuels. Sediment
Use of these fuels can result in higher maintenance Water 0.1% maximum “D1744”
costs and in reduced engine service life.
Sediment 0.05% maximum
“D473”
Diesel fuels that meet the specifications in Table (weight)
7 will help to provide maximum engine service life (continued)
and performance. In North America, diesel fuel that
is identified as No. 2-D in “ASTM D975” generally
meets the specifications. Table 7 is for diesel fuels
that are distilled from crude oil. Diesel fuels from
other sources could exhibit detrimental properties
that are not defined or controlled by this specification.
40
Maintenance Section
Fuel Specifications

(Table 7, contd) Table 8

Gum and Resins 10 mg per 100 Distillate Fuels (1)
“D381”
(3) mL maximum
Specification Grade
Lubricity (4) 0.38 mm
(0.015 inch) “MIL-T-5624R” JP-5
“D6079”
maximum at “ASTM D1655” Jet-A-1
25 °C (77 °F)
(1) Perkins fuel systems and engine components can operate
“MIL-T-83133D” JP-8
on high sulfur fuels. Fuel sulfur levels affect exhaust (1) The fuels that are listed in this Table may not meet the
emissions. High sulfur fuels also increase the potential for requirements that are specified in the “Perkins Specifications
corrosion of internal components. Fuel sulfur levels above 0.5 for Distillate Diesel Fuel” Table. Consult the supplier for the
percent may significantly shorten the oil change interval. For recommended additives in order to maintain the proper fuel
additional information, see this publication, “Engine Oil” topic lubricity.
(Maintenance Section).
(2) The values of the fuel viscosity are the values as the fuel
is delivered to the fuel injection pumps. If a fuel with a low
These fuels are lighter than the No. 2 grades of fuel.
viscosity is used, cooling of the fuel may be required to The cetane number of the fuels in Table 8 must be
maintain a 1.4 cSt viscosity at the fuel injection pump. Fuels at least 40. If the viscosity is below 1.4 cSt at 38 °C
with a high viscosity might require fuel heaters in order to bring (100 °F), use the fuel only in temperatures below
down the viscosity to a 20 cSt viscosity.
(3)
0 °C (32 °F). Do not use any fuels with a viscosity
Follow the test conditions and procedures for gasoline (motor).
(4) The lubricity of a fuel is a concern with low sulfur fuel. To
of less than 1.2 cSt at 38 °C (100 °F). Fuel cooling
determine the lubricity of the fuel, use either the “ASTM D6078 may be required in order to maintain the minimum
Scuffing Load Wear Test (SBOCLE)” or the “ASTM D6079 High viscosity of 1.4 cSt at the fuel injection pump.
Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a
fuel does not meet the minimum requirements, consult your There are many other diesel fuel specifications that
fuel supplier. Do not treat the fuel without consulting the fuel
supplier. Some additives are not compatible. These additives
are published by governments and by technological
can cause problems in the fuel system. societies. Usually, those specifications do not
review all the requirements that are addressed
in this specification. To ensure optimum engine
NOTICE performance, a complete fuel analysis should be
Operating with fuels that do not meet the Perkins rec- obtained before engine operation. The fuel analysis
ommendations can cause the following effects: Start- should include all of the properties that are listed in
ing difficulty, poor combustion, deposits in the fuel in- Table 7.
jectors, reduced service life of the fuel system, de-
posits in the combustion chamber, and reduced ser-
vice life of the engine.

NOTICE
Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel
must NOT be used in Perkins diesel engines. Severe
component wear and component failures will result if
HFO type fuels are used in engines that are configured
to use distillate fuel.

In extreme cold ambient conditions, you may use the

distillate fuels that are specified in Table 8. However,
the fuel that is selected must meet the requirements
that are specified in Table 7. These fuels are intended
to be used in operating temperatures that are down
to −54 °C (−65 °F).
 41
Maintenance Section
Cooling System Specifications

Cooling System Water

Specifications Water is used in the cooling system in order to
transfer heat.

i01908149 Distilled water or deionized water is

recommended for use in engine cooling systems.
General Coolant Information
DO NOT use the following types of water in cooling
systems: Hard water, softened water that has been
conditioned with salt, and sea water.
NOTICE
Never add coolant to an overheated engine. Engine If distilled water or deionized water is not available,
damage could result. Allow the engine to cool first. use water with the properties that are listed in Table 9.

Table 9
NOTICE Perkins Minimum Acceptable Water Requirements
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system Property Maximum Limit
must be either protected to the lowest outside temper-
Chloride (Cl) 40 mg/L
ature or drained completely to prevent damage.
Sulfate (SO4) 100 mg/L

NOTICE Total Hardness 170 mg/L

Frequently check the specific gravity of the coolant for Total Solids 340 mg/L
proper freeze protection or for anti-boil protection.
Acidity pH of 5.5 to 9.0

Clean the cooling system for the following reasons:

For a water analysis, consult one of the following
sources:
• Contamination of the cooling system
• Overheating of the engine • Local water utility company

• Foaming of the coolant • Agricultural agent

• Independent laboratory
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature Additives
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob- Additives help to protect the metal surfaces of
lems can develop without water temperature regula- the cooling system. A lack of coolant additives or
tors. insufficient amounts of additives enable the following
conditions to occur:

Many engine failures are related to the cooling • Corrosion

system. The following problems are related to cooling
system failures: Overheating, leakage of the water • Formation of mineral deposits
pump, and plugged radiators or heat exchangers.
• Rust
These failures can be avoided with proper cooling
system maintenance. Cooling system maintenance is • Scale
as important as maintenance of the fuel system and
the lubrication system. Quality of the coolant is as • Foaming of the coolant
important as the quality of the fuel and the lubricating
oil. Many additives are depleted during engine operation.
These additives must be replaced periodically. .
Coolant is normally composed of three elements:
Water, additives, and glycol. Additives must be added at the proper concentration.
Overconcentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can
enable the following problems to occur:
42
Maintenance Section
Cooling System Specifications

• Formation of gel compounds i01946006

• Reduction of heat transfer Coolant Recommendations

• Leakage of the water pump seal
• Plugging of radiators, coolers, and small passages The following two coolants are used in Perkins diesel
engines:
Glycol Preferred – Perkins Extended Life Coolant (ELC)
Glycol in the coolant helps to provide protection Acceptable – A commercial heavy-duty
against the following conditions: coolant/antifreeze that meets “ASTM D4985”
specifications
• Boiling
• Freezing NOTICE
Do not use a commercial coolant/antifreeze that on-
• Cavitation of the water pump ly meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light automotive appli-
For optimum performance, Perkins recommends a cations.
1:1 mixture of a water/glycol solution.
Perkins recommends a 1:1 mixture of water
Note: Use a mixture that will provide protection and glycol. This mixture of water and glycol will
against the lowest ambient temperature. provide optimum heavy-duty performance as a
coolant/antifreeze. This ratio may be increased to 1:2
Note: 100 percent pure glycol will freeze at a water to glycol if extra freezing protection is required.
temperature of −23 °C (−9 °F).
Note: A commercial heavy-duty coolant/antifreeze
Most conventional coolant/antifreezes use ethylene that meets “ASTM D4985” specifications MAY require
glycol. Propylene glycol may also be used. In a 1:1 a treatment with an SCA at the initial fill. Read the
mixture with water, ethylene and propylene glycol label or the instructions that are provided by the OEM
provide similar protection against freezing and of the product.
boiling. See Tables 10 and 11.
In stationary engine applications and marine engine
Table 10 applications that do not require anti-boil protection
Ethylene Glycol or freeze protection, a mixture of SCA and water
is acceptable. Perkins recommends a six percent
Freeze Boil to eight percent concentration of SCA in those
Concentration
Protection Protection
cooling systems. Distilled water or deionized water
50 Percent −36 °C (−33 °F) 106 °C (223 °F) is preferred. Water which has the recommended
properties may be used.
60 Percent −51 °C (−60 °F) 111 °C (232 °F)
Engines that are operating in an ambient temperature
NOTICE above 43 °C (109.4 °F) must use SCA and water.
Do not use propylene glycol in concentrations that ex- Engines that operate in an ambient temperature
ceed 50 percent glycol because of propylene glycol’s above 43 °C (109.4 °F) and below 0 °C (32 °F) due
reduced heat transfer capability. Use ethylene glycol to seasonal variations. Consult your Perkins dealer
in conditions that require additional protection against or your Perkins distributor for the correct level of
boiling or freezing. protection.

Table 11
Propylene Glycol
Freeze Anti-Boil
Concentration
Protection Protection
50 Percent −29 °C (−20 °F) 106 °C (223 °F)

To check the concentration of glycol in the coolant,

measure the specific gravity of the coolant.
 43
Maintenance Section
Cooling System Specifications

Table 12 i01946026

Coolant Service Life Extended Life Coolant (ELC)

Coolant Type Service Life Cooling System Maintenance
12,000 Service Hours
Perkins ELC
or Six Years
Commercial Heavy-Duty
Coolant/Antifreeze that
3000 Service Hours or
Two Years
Proper additions to the Extended
meets “ASTM D4985”
Life Coolant
Perkins POWERPART 3000 Service Hours or
SCA Two Years NOTICE
Commercial SCA and 3000 Service Hours or Use only Perkins products for pre-mixed or concen-
Water Two Years trated coolants.

Use only Perkins Extender with Extended Life

i01946021 Coolant.

Extended Life Coolant (ELC) Mixing Extended Life Coolant with other products re-
duces the Extended Life Coolant service life. Failure to
follow the recommendations can reduce cooling sys-
tem components life unless appropriate corrective ac-
Perkins provides Extended Life Coolant (ELC) for tion is performed.
use in the following applications:
In order to maintain the correct balance between
• Heavy-duty spark ignited gas engines the antifreeze and the additives, you must maintain
the recommended concentration of Extended Life
• Heavy-duty diesel engines Coolant (ELC). Lowering the proportion of antifreeze
lowers the proportion of additive. This will lower the
• Automotive applications
ability of the coolant to protect the system from pitting,
The anti-corrosion package for ELC is different from from cavitation, from erosion, and from deposits.
the anti-corrosion package for other coolants. ELC
is an ethylene glycol base coolant. However, ELC NOTICE
contains organic corrosion inhibitors and antifoam Do not use a conventional coolant to top-off a cooling
agents with low amounts of nitrite. Perkins ELC system that is filled with Extended Life Coolant (ELC).
has been formulated with the correct amount of
these additives in order to provide superior corrosion Do not use standard supplemental coolant additive
protection for all metals in engine cooling systems. (SCA). Only use ELC Extender in cooling systems that
are filled with ELC.
ELC extends the service life of the coolant to 12000
service hours or six years. ELC does not require
a frequent addition of a Supplemental Coolant Perkins ELC Extender
Additive (SCA). An Extender is the only additional
maintenance that is needed at 6000 service hours or ELC Extender is added to the cooling system halfway
one half of the ELC service life. through the ELC service life. Treat the cooling system
with ELC Extender at 6000 hours or one half of
ELC is available in a 1:1 premixed cooling solution the coolant service life. Use Table 13 in order to
with distilled water. The Premixed ELC provides determine the proper amount of ELC Extender that
freeze protection to −36 °C (−33 °F). The Premixed is required.
ELC is recommended for the initial fill of the cooling
system. The Premixed ELC is also recommended for Containers of several sizes are available. Consult
topping off the cooling system. your Perkins dealer for the part numbers.

ELC Concentrate is also available. ELC Concentrate Use the formula in Table 13 to determine the proper
can be used to lower the freezing point to −51 °C amount of ELC Extender for your cooling system.
(−60 °F) for arctic conditions. Refer to Operation and Maintenance Manual, “Refill
Capacities” in order to determine the capacity of the
Containers of several sizes are available. Consult cooling system.
your Perkins dealer for the part numbers.
44
Maintenance Section
Cooling System Specifications

Table 13
Formula For Adding ELC Extender To ELC NOTICE
Care must be taken to ensure that all fluids are
V × 0.02 = X contained during performance of inspection, main-
V is the total capacity of the cooling system. tenance, testing, adjusting and the repair of the
product. Be prepared to collect the fluid with suitable
X is the amount of ELC Extender that is required. containers before opening any compartment or dis-
assembling any component containing fluids.
Table 14 is an example for using the formula that is
in Table 13. Dispose of all fluids according to local regulations and
mandates.
Table 14

Example Of The Equation For Adding ELC 1. Drain the coolant into a suitable container.
Extender To ELC
2. Dispose of the coolant according to local
Total Volume Multiplication Amount of ELC
of the Cooling Factor Extender that is regulations.
System (V) Required (X)
3. Flush the system with clean water in order to
9 L (2.4 US gal) × 0.02 0.18 L remove any debris.
(0.05 US gal)
or (6 fl oz) 4. Use Perkins cleaner to clean the system. Follow
the instruction on the label.
NOTICE
When using Perkins ELC, do not use standard SCA’s 5. Drain the cleaner into a suitable container. Flush
or SCA filters. the cooling system with clean water.

6. Fill the cooling system with clean water and

ELC Cooling System Cleaning operate the engine until the engine is warmed to
49° to 66°C (120° to 150°F).
Note: If the cooling system is already using ELC,
cleaning agents are not required to be used at NOTICE
the specified coolant change interval. Cleaning Improper or incomplete flushing of the cooling system
agents are only required if the system has been can result in damage to copper and other metal com-
contaminated by the addition of some other type of ponents.
coolant or by cooling system damage.
To avoid damage to the cooling system, make sure to
Clean water is the only cleaning agent that is required completely flush the cooling system with clear water.
when ELC is drained from the cooling system. Continue to flush the system until all the signs of the
cleaning agent are gone.
After the cooling system is drained and after the
cooling system is refilled, operate the engine while
the cooling system filler cap is removed. Operate 7. Drain the cooling system into a suitable container
the engine until the coolant level reaches the normal and flush the cooling system with clean water.
operating temperature and until the coolant level
stabilizes. As needed, add the coolant mixture in Note: The cooling system cleaner must be thoroughly
order to fill the system to the specified level. flushed from the cooling system. Cooling system
cleaner that is left in the system will contaminate the
coolant. The cleaner may also corrode the cooling
Changing to Perkins ELC system.
To change from heavy-duty coolant/antifreeze to the 8. Repeat Steps 6 and 7 until the system is
Perkins ELC, perform the following steps: completely clean.

9. Fill the cooling system with the Perkins premixed

ELC.
 45
Maintenance Section
Cooling System Specifications

ELC Cooling System Perkins engine cooling systems should be tested

at 500 hour intervals for the concentration of
Contamination Supplemental Coolant Additive (SCA).
NOTICE Additions of SCA are based on the results of the test.
Mixing ELC with other products reduces the effective- An SCA that is liquid may be needed at 500 hour
ness of the ELC and shortens the ELC service life. intervals.
Use only Perkins Products for premixed or concen-
trate coolants. Use only Perkins ELC extender with Refer to Table 15 for part numbers and for quantities
Perkins ELC. Failure to follow these recommenda- of SCA.
tions can result in shortened cooling system compo-
nent life. Table 15
Perkins Liquid SCA
ELC cooling systems can withstand contamination to
a maximum of ten percent of conventional heavy-duty Part Number Quantity
coolant/antifreeze or SCA. If the contamination 21825755 .
exceeds ten percent of the total system capacity,
perform ONE of the following procedures:
Adding the SCA to Heavy-Duty
• Drain the cooling system into a suitable container. Coolant at the Initial Fill
Dispose of the coolant according to local
regulations. Flush the system with clean water. Fill
Commercial heavy-duty coolant/antifreeze that
the system with the Perkins ELC.
meets “ASTM D4985” specifications MAY require
an addition of SCA at the initial fill. Read the label
• Drain a portion of the cooling system into a suitable or the instructions that are provided by the OEM of
container according to local regulations. Then, fill
the product.
the cooling system with premixed ELC. This should
lower the contamination to less than 10 percent.
Use the equation that is in Table 16 to determine the
amount of Perkins SCA that is required when the
• Maintain the system as a conventional Heavy Duty cooling system is initially filled.
Coolant. Treat the system with an SCA. Change
the coolant at the interval that is recommended for Table 16
the conventional Heavy Duty Coolant.
Equation For Adding The SCA To Heavy-Duty
Coolant At The Initial Fill
i01946221
V × 0.045 = X
Commercial Heavy-Duty V is the total volume of the cooling system.
Coolant/Antifreeze and SCA X is the amount of SCA that is required.

Table 17 is an example for using the equation that

is in Table 16.
NOTICE
Commercial Heavy-Duty Coolant which contains Table 17
Amine as part of the corrision protection system must
not be used. Example Of The Equation For Adding The SCA
To Heavy-Duty Coolant At The Initial Fill
Total Volume Multiplication Amount of SCA
NOTICE of the Cooling Factor that is Required
Never operate an engine without water temperature System (V) (X)
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the 15 L (4 US gal) × 0.045 0.7 L (24 oz)
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors. Adding the SCA to Heavy-Duty
Coolant For Maintenance
Check the coolant/antifreeze (glycol concentration)
in order to ensure adequate protection against Heavy duty coolant/antifreeze of all types REQUIRE
boiling or freezing. Perkins recommends the use of a periodic additions of an SCA.
refractometer for checking the glycol concentration.
46
Maintenance Section
Cooling System Specifications

Test the coolant/antifreeze periodically for the

concentration of SCA. For the interval, see the
Operation and Maintenance Manual, “Maintenance
Interval Schedule” (Maintenance Section). Test the
concentration of SCA.

Additions of SCA are based on the results of the

test. The size of the cooling system determines the
amount of SCA that is needed.

Use the equation that is in Table 18 to determine the

amount of Perkins SCA that is required, if necessary:

Table 18
Equation For Adding The SCA To Heavy-Duty
Coolant For Maintenance
V × 0.014 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.

Table 19 is an example for using the equation that

is in Table 18.

Table 19

Example Of The Equation For Adding The SCA To

Heavy-Duty Coolant For Maintenance
Total Volume Multiplication Amount of SCA
of the Cooling Factor that is Required
System (V) (X)
15 L (4 US gal) × 0.014 0.2 L (7 oz)

Cleaning the System of Heavy-Duty

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

• Clean the cooling system after used coolant is

drained or before the cooling system is filled with
new coolant.

• Clean the cooling system whenever the coolant is

contaminated or whenever the coolant is foaming.
 47
Maintenance Section
Refill Capacities

Refill Capacities
i01935403

Refill Capacities

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

Table 20

Approximate Refill Capacity of the

Lubrication System
Compartment or System Liters Pints
Crankcase Oil Sump(1) 10 17.6
(1) These values are the approximate capacities for the crankcase
oil sump which include the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.

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

Table 21
Approximate Refill Capacity of the Cooling System
Compartment or System Liters Pints
Engine Only 5.5 9.7
External Cooling System (OEM
Recommendation)(1)
Total Cooling System(2)
(1) The external cooling system includes a radiator or an expansion
tank with the following components: The heat exchanger, the
aftercooler, and the piping Refer to the Perkins specifications
and/or the OEM specifications. Enter the value for the external
cooling system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine
cooling system plus the capacity for the external cooling
system. Enter the total in this row.
48
Maintenance Section
Maintenance Interval Schedule

i01949611 Every 2000 Service Hours

Maintenance Interval Schedule Engine Mounts - Inspect ....................................... 57

Every 2 Years
Ensure that the Safety Information, Warnings, Cooling System Coolant - Change ....................... 52
and Instructions are read and understood
before operation or maintenance procedures are Every 3000 Service Hours
performed.
Water Pump - Inspect ........................................... 67
Before each consecutive interval is performed, all
of the maintenance requirements from the previous Every 6000 Service Hours or 3 Years
interval must also be performed.
Cooling System Coolant Extender (ELC) - Add .... 54
When Required Every 12 000 Service Hours or 6 Years
Battery - Replace .................................................. 50
Cooling System Coolant (ELC) - Change ............. 51
Battery or Battery Cable - Disconnect .................. 51
Engine - Clean ...................................................... 56
Engine Air Cleaner Element (Single Element) -
Inspect/Replace .................................................. 56
Fuel System - Prime ............................................. 60
Severe Service Application - Check ..................... 65

Daily
Cooling System Coolant Level - Check ................ 54
Driven Equipment - Check .................................... 56
Engine Air Cleaner Service Indicator - Inspect ..... 57
Engine Oil Level - Check ...................................... 58
Fuel System Primary Filter/Water Separator -
Drain ................................................................... 62
Walk-Around Inspection ........................................ 67

Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 62

Every 500 Service Hours or 6 Months

Alternator and Fan Belts - Inspect/Adjust/
Replace ............................................................... 49

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 50
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 55
Engine Oil and Filter - Change ............................. 58
Fuel System Filter - Replace ................................ 61
Hoses and Clamps - Inspect/Replace .................. 63
Radiator - Clean .................................................... 64

Every 1000 Service Hours

Alternator - Inspect ............................................... 49
Engine Valve Lash - Inspect/Adjust ...................... 60
Starting Motor - Inspect ........................................ 65
Turbocharger - Inspect .......................................... 66
 49
Maintenance Section
Alternator - Inspect

i01908658 Adjustment
Alternator - Inspect

Perkins recommends a scheduled inspection of

the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system. Make
repairs, as required.

Check the alternator and the battery charger for

proper operation. If the batteries are properly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. When the
engine is not run for long periods of time or if the
engine is run for short periods, the batteries may not
g00987404
fully charge. A battery with a low charge will freeze Illustration 18
more easily than a battery with a full charge. Typical example
(1) Mounting bolts
(2) Alternator
i01896863 (3) Bracket
(4) Belt
Alternator and Fan Belts -
Inspect/Adjust/Replace 1. Loosen mounting bolts (1) .

2. Move the alternator (2) in order to increase or

decrease the belt tension. To check the belt
tension, apply 45 N (10 lb ft) of force midway
Inspection between the pulleys. A correctly adjusted belt will
deflect 10 mm (0.39 inch).
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are 3. Tighten mounting bolts (1).
worn or damaged.

For applications that require multiple drive belts, Replacement

replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to 1. Remove the tension from the belt by loosening
carry more load because the older belt is stretched. the mounting bolts (1).
The additional load on the new belt could cause the
new belt to break. 2. Remove the belt (4).

If the belts are too loose, vibration causes 3. Install the new belt.
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating. 4. Move the alternator (2) in order to increase or
decrease the belt tension. To check the belt
To check the belt tension, apply 45 N (10 lb ft) of force tension, apply 45 N (10 lb ft) of force midway
midway between the pulleys. A correctly adjusted between the pulleys. A correctly adjusted belt will
belt will deflect 10 mm (0.39 inch). deflect 10 mm (0.39 inch).

When new belts are installed, check the belt tension

again after 20 hours of engine operation.
50
Maintenance Section
Battery - Replace

i01878164 8. Connect the cable from the NEGATIVE “-” terminal

on the starter motor to the NEGATIVE “-” battery
Battery - Replace terminal.

i01908638

Battery Electrolyte Level -

Batteries give off combustible gases which can Check
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.
When the engine is not run for long periods of time or
Ensure proper ventilation for batteries that are in when the engine is run for short periods, the batteries
an enclosure. Follow the proper procedures in or- may not fully recharge. Ensure a full charge in order
der to help prevent electrical arcs and/or sparks to help prevent the battery from freezing. If batteries
near batteries. Do not smoke when batteries are are properly charged, ammeter reading should be
serviced. very near zero.

All lead-acid batteries contain sulfuric acid which

The battery cables or the batteries should not be can burn the skin and clothing. Always wear a face
removed with the battery cover in place. The bat- shield and protective clothing when working on or
tery cover should be removed before any servic- near batteries.
ing is attempted.

Removing the battery cables or the batteries with 1. Remove the filler caps. Maintain the electrolyte
the cover in place may cause a battery explosion level to the “FULL” mark on the battery.
resulting in personal injury.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
1. Switch the engine to the OFF position. Remove water that is low in minerals. Do not use artificially
all electrical loads. softened water.
2. Turn off any battery chargers. Disconnect any 2. Check the condition of the electrolyte with a
battery chargers. suitable battery tester.
3. The NEGATIVE “-” cable connects the NEGATIVE 3. Keep the batteries clean.
“-” battery terminal to the NEGATIVE “-” terminal
on the starter motor. Disconnect the cable from Clean the battery case with one of the following
the NEGATIVE “-” battery terminal. cleaning solutions:
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the POSITIVE “+” terminal
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
on the starting motor. Disconnect the cable from
the POSITIVE “+” battery terminal.
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate Thoroughly rinse the battery case with clean water.
recycling facility.
Use a fine grade of sandpaper to clean the
5. Remove the used battery. terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
6. Install the new battery. remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Note: Before the cables are connected, ensure that Coat the clamps and the terminals with a suitable
the engine start switch is OFF. silicone lubricant or petroleum jelly.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
 51
Maintenance Section
Battery or Battery Cable - Disconnect

i01492654 Clean the cooling system and flush the cooling

system before the recommended maintenance
Battery or Battery Cable - interval if the following conditions exist:
Disconnect
• The engine overheats frequently.
• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
The battery cables or the batteries should not be
removed with the battery cover in place. The bat- • The fuel has entered the cooling system and the
tery cover should be removed before any servic- coolant is contaminated.
ing is attempted.
Note: When the cooling system is cleaned, only
Removing the battery cables or the batteries with clean water is needed when the ELC is drained and
the cover in place may cause a battery explosion replaced.
resulting in personal injury.
Note: Inspect the water pump and the water
1. Turn the start switch to the OFF position. Turn the temperature regulator after the cooling system has
ignition switch (if equipped) to the OFF position been drained. This is a good opportunity to replace
and remove the key and all electrical loads. the water pump, the water temperature regulator and
the hoses, if necessary.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that Drain
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.

3. Tape the leads in order to help prevent accidental Pressurized System: Hot coolant can cause seri-
starting. ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
4. Proceed with necessary system repairs. Reverse components are cool. Loosen the cooling system
the steps in order to reconnect all of the cables. pressure cap slowly in order to relieve the pres-
sure.

i01946512
1. Stop the engine and allow the engine to cool.
Cooling System Coolant (ELC) Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
- Change system filler cap.

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

Dispose of all fluids according to Local regulations and

mandates.

NOTICE Illustration 19
g00987502
Keep all parts clean from contaminants.
2. Open the drain cock or remove the drain plug (1)
Contaminants may cause rapid wear and shortened on the engine. Open the drain cock or remove the
component life. drain plug on the radiator.
52
Maintenance Section
Cooling System Coolant - Change

Allow the coolant to drain. 2. Fill the cooling system with Extended Life Coolant
(ELC). Refer to the Operation and Maintenance
NOTICE Manual, “Cooling System Specifications” topic
Dispose of used engine coolant or recycle. Various (Maintenance Section) for more information on
methods have been proposed to reclaim used coolant cooling system specifications. Do not install the
for reuse in engine cooling systems. The full distillation cooling system filler cap.
procedure is the only method acceptable by Perkins to
reclaim the coolant. 3. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
For information regarding the disposal and the the cavities of the engine block. Stop the engine.
recycling of used coolant, consult your Perkins dealer
or your Perkins distributor. 4. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
Flush pipe for filling. Maintain the coolant level in the
expansion bottle (if equipped) at the proper level.
1. Flush the cooling system with clean water in order
to remove any debris. 5. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
2. Close the drain cock or install the drain plug in the the gasket that is on the cooling system filler cap
engine. Close the drain cock or install the drain is damaged, discard the old cooling system filler
plug on the radiator. cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap
is not damaged, use a suitable Pressurizing Pump
NOTICE
in order to pressure test the cooling system filler
Do not fill the cooling system faster than 5 L
cap. The correct pressure for the cooling system
(1.3 US gal) per minute to avoid air locks.
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
Cooling system air locks may result in engine damage.
does not retain the correct pressure, install a new
cooling system filler cap.
3. Fill the cooling system with clean water. Install the
cooling system filler cap. 6. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
i01946911

5. Stop the engine and allow the engine to cool. Cooling System Coolant -
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling Change
system filler cap. Open the drain cock or remove
the drain plug on the engine. Open the drain cock
(Commercial Heavy Duty)
or remove the drain plug on the radiator. Allow
the water to drain. Flush the cooling system with
clean water.
NOTICE
Care must be taken to ensure that fluids are contained
Fill during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
1. Close the drain cock or install the drain plug on collect the fluid with suitable containers before open-
the engine. Close the drain cock or install the ing any compartment or disassembling any compo-
drain plug on the radiator. nent containing fluids.

NOTICE Dispose of all fluids according to Local regulations and

Do not fill the cooling system faster than 5 L mandates.
(1.3 US gal) per minute to avoid air locks.
NOTICE
Cooling system air locks may result in engine damage.
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.
 53
Maintenance Section
Cooling System Coolant - Change

Clean the cooling system and flush the cooling

system before the recommended maintenance NOTICE
interval if the following conditions exist: Dispose of used engine coolant or recycle. Various
methods have been proposed to reclaim used coolant
• The engine overheats frequently. for reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Perkins to
• Foaming is observed. reclaim the coolant.

• The oil has entered the cooling system and the For information regarding the disposal and the
coolant is contaminated.
recycling of used coolant, consult your Perkins dealer
or your Perkins distributor.
• The fuel has entered the cooling system and the
coolant is contaminated.
Flush
Note: When the cooling system is cleaned, only
clean water is needed. 1. Flush the cooling system with clean water in order
to remove any debris.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has 2. Close the drain cock or install the drain plug in the
been drained. This is a good opportunity to replace engine. Close the drain cock or install the drain
the water pump, the water temperature regulator and plug on the radiator.
the hoses, if necessary.
NOTICE
Drain 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.

Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, 3. Fill the cooling system with clean water. Install the
stop the engine and wait until the cooling system cooling system filler cap.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- 4. Start and run the engine at low idle until the
sure. temperature reaches 49 to 66 °C (120 to 150 °F).

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

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

NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
g00987502
Illustration 20
Cooling system air locks may result in engine damage.
2. Open the drain cock or remove the drain plug (1)
on the engine. Open the drain cock or remove the
drain plug on the radiator.

Allow the coolant to drain.

54
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

2. Fill the cooling system with Commercial 3. Add Extender according to the requirements for
Heavy-Duty Coolant. Add Supplemental your engine’s cooling system capacity. Refer to
Coolant Additive to the coolant. For the correct the Operation and Maintenance Manual, “Refill
amount, refer to the Operation and Maintenance Capacities” in the Maintenance Section for the
Manual, “Cooling System Specifications” topic capacity of the cooling system for your engine.
(Maintenance Section) for more information on Refer to the Operation and Maintenance Manual,
cooling system specifications. Do not install the “Cooling System Specifications” information for
cooling system filler cap. the Perkins ELC Extender.

3. Start and run the engine at low idle. Increase the 4. Clean the cooling system filler cap. Inspect the
engine rpm to high idle. Run the engine at high gasket of the cooling system filler cap. If the gasket
idle for one minute in order to purge the air from is damaged then replace the cooling system filler
the cavities of the engine block. Stop the engine. cap. Install the cooling system filler cap.

4. Check the coolant level. Maintain the coolant level

i01935755
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level in the
expansion bottle (if equipped) at the proper level.
Cooling System Coolant Level
- Check
5. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler Engines With a Coolant Recovery
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap Tank
is not damaged, use a suitable Pressurizing Pump
in order to pressure test the cooling system filler Note: The cooling system may not have been
cap. The correct pressure for the cooling system provided by Perkins. The procedure that follows
filler cap is stamped on the face of the cooling is for typical cooling systems. Refer to the OEM
system filler cap. If the cooling system filler cap information for the correct procedures.
does not retain the correct pressure, install a new
cooling system filler cap. Check the coolant level when the engine is stopped
and cool.
6. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature. 1. Observe the coolant level in the coolant recovery
tank. Maintain the coolant level to “COLD FULL”
mark on the coolant recovery tank.
i01946540

Cooling System Coolant

Extender (ELC) - Add Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
The Perkins Extended Life Coolant (ELC) does not
pressure cap slowly in order to relieve the pres-
need the frequent addition of Supplemental Coolant
sure.
Additives (SCA) associated with conventional
coolants. The Extender only needs to be added once.
2. Loosen filler cap slowly in order to relieve any
Check the cooling system only when the engine is pressure. Remove the filler cap.
stopped and cool.
3. Pour the proper coolant mixture into the tank.
1. Loosen the cooling system filler cap slowly in Refer to the Operation and Maintenance Manual,
order to relieve pressure. Remove the cooling “Cooling System Specifications” for information on
system filler cap. the correct mixture and type of coolant. Refer to
the Operation and Maintenance Manual, “Refill
2. It may be necessary to drain enough coolant from Capacities” for the cooling system capacity. Do
the cooling system in order to add the Extender. not fill the coolant recovery tank above “COLD
FULL” mark.
 55
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

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

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

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
damaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i01946566

Illustration 21
g00103639 Cooling System Supplemental
Coolant Additive (SCA) -
4. Clean filler cap and the receptacle. Reinstall the
filler cap and inspect the cooling system for leaks. Test/Add
Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional
volume will be forced into the coolant recovery tank
during engine operation. When the engine is stopped
and cool, the coolant will return to the engine. Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with
Engines Without a Coolant the skin and the eyes. Do not drink cooling system
coolant additive.
Recovery Tank
Check the coolant level when the engine is stopped Test for SCA Concentration
and cool.
Heavy-Duty Coolant/Antifreeze and SCA

NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.

Use a Coolant Conditioner Test Kit in order to check

the concentration of the SCA.

Add the SCA, If Necessary

NOTICE
Illustration 22
g00285520 Do not exceed the recommended amount of sup-
Cooling system filler cap
plemental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
cooling system, reducing the engine’s heat transfer
characteristics. Reduced heat transfer could cause
Pressurized System: Hot coolant can cause seri- cracking of the cylinder head and other high temper-
ous burns. To open the cooling system filler cap, ature components. Excessive supplemental coolant
stop the engine and wait until the cooling system additive concentration could also result in radiator
components are cool. Loosen the cooling system tube blockage, overheating, and/or accelerated water
pressure cap slowly in order to relieve the pres- pump seal wear. Never use both liquid supplemental
sure. coolant additive and the spin-on element (if equipped)
at the same time. The use of those additives together
could result in supplemental coolant additive concen-
1. Remove the cooling system filler cap slowly in
tration exceeding the recommended maximum.
order to relieve pressure.
56
Maintenance Section
Driven Equipment - Check

i01936072

Engine - Clean
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
Personal injury or death can result from high volt-
age.
1. Slowly loosen the cooling system filler cap in
order to relieve the pressure. Remove the cooling Moisture can create paths of electrical conductiv-
system filler cap. ity.

Note: Always discard drained fluids according to Make sure that the electrical system is OFF. Lock
local regulations. out the starting controls and tag the controls “DO
NOT OPERATE”.
2. If necessary, drain some coolant from the cooling
system into a suitable container in order to allow
space for the extra SCA. NOTICE
Accumulated grease and oil on an engine is a fire haz-
3. Add the proper amount of SCA. Refer to the ard. Keep the engine clean. Remove debris and fluid
Operation and Maintenance Manual, “Commercial spills whenever a significant quantity accumulates on
Heavy-Duty Antifreeze and SCA” for more the engine.
information on SCA requirements.
Periodic cleaning of the engine is recommended.
4. Clean the cooling system filler cap. Inspect the
Steam cleaning the engine will remove accumulated
gaskets of the cooling system filler cap. If the
oil and grease. A clean engine provides the following
gaskets are damaged, replace the old cooling
benefits:
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.
• Easy detection of fluid leaks
i00174798 • Maximum heat transfer characteristics
Driven Equipment - Check • Ease of maintenance
Note: Caution must be used in order to prevent
electrical components from being damaged by
Refer to the OEM specifications for more information excessive water when the engine is cleaned.
on the following maintenance recommendations for Pressure washers and steam cleaners should not be
the driven equipment: directed at any electrical connectors or the junction of
cables into the rear of the connectors. Avoid electrical
• Inspection components such as the alternator, and the starter.
Protect the fuel injection pump from fluids in order
• Adjustment to wash the engine.

• Lubrication
i01897734

• Other maintenance recommendations Engine Air Cleaner

Perform any maintenance for the driven equipment Element (Single Element) -
which is recommended by the OEM.
Inspect/Replace

Refer to Operation and Maintenance Manual, “Engine

Air Cleaner Service Indicator-Inspect”.
 57
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Observe the service indicator. The air cleaner

NOTICE element should be cleaned or the air cleaner element
Never run the engine without an air cleaner element should be replaced when one of the following
installed. Never run the engine with a damaged air conditions occur:
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the • The yellow diaphragm enters the red zone.
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air- • The red piston locks in the visible position.
borne debris from entering the air inlet.
Test the Service Indicator
NOTICE Service indicators are important instruments.
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
• Check for ease of resetting. The service indicator
should reset in less than three pushes.
A wide variety of air cleaners may be installed for use
with this engine. Consult the OEM information for the • Check the movement of the yellow core when the
proper procedure to replace the air cleaner. engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.
i01936073
If the service indicator does not reset easily, or if the
Engine Air Cleaner Service yellow core does not latch at the greatest vacuum,
Indicator - Inspect the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be restricted.

Some engines may be equipped with a different The service indicator may need to be replaced
service indicator. frequently in environments that are severely dusty.

Some engines are equipped with a differential gauge

i01908586
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
Engine Mounts - Inspect
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is Note: The engine mounts may not have been
equipped with a different type of service indicator, supplied for this installation by Perkins. Refer to the
follow the OEM recommendations in order to service OEM information for further information on the engine
the air cleaner service indicator. mounts and the correct bolt torque.
The service indicator may be mounted on the air Inspect the engine mounts for deterioration and for
cleaner element or in a remote location. correct bolt torque. Engine vibration can be caused
by the following conditions:

• Improper mounting of the engine

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

g00103777
Illustration 23
Typical service indicator
58
Maintenance Section
Engine Oil Level - Check

i01897042
NOTICE
Engine Oil Level - Check Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to Dispose of all fluids according to local regulations and
contact the skin. mandates.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Illustration 24
g00986928 Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the bottom
(Y) minimum “MIN” mark. (X) maximum “MAX” mark.
of the oil pan. The waste particles are not removed
with the draining cold oil. Drain the crankcase with
NOTICE the engine stopped. Drain the crankcase with the
Perform this maintenance with the engine stopped. oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained
properly.
1. Maintain the oil level between minimum “MIN”
mark (Y) and the maximum “MAX” mark (X) on oil Failure to follow this recommended procedure will
level gauge (1). Do not fill the crankcase above cause the waste particles to be recirculated through
“MAX” mark (X). the engine lubrication system with the new oil.

NOTICE Drain the Engine Oil

Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into After the engine has been run at the normal operating
the oil. The air bubbles created from the crankshaft temperature, stop the engine. Use one of the
dipping into the oil reduces the oil’s lubricating char- following methods to drain the engine crankcase oil:
acteristics and could result in the loss of power.
• If the engine is equipped with a drain valve, turn the
2. Remove the oil filler cap and add oil, if necessary. drain valve knob counterclockwise in order to drain
Clean the oil filler cap. Install the oil filler cap. the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
i01936100
• If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil
Engine Oil and Filter - Change to drain.

After the oil has drained, the oil drain plugs should
be cleaned and installed.

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
 59
Maintenance Section
Engine Oil and Filter - Change

Replace the Oil Filter

NOTICE
Perkins oil filters are built to Perkins specifications.
Use of an oil filter not recommended by Perkins could
result in severe engine damage to the engine bear-
ings, crankshaft, etc., as a result of the larger waste
particles from unfiltered oil entering the engine lubri-
cating system. Only use oil filters recommended by
Perkins.

1. Remove the oil filter with a suitable chain wrench.

Note: The following actions can be carried out as

part of the preventive maintenance program.

2. Cut the oil filter open with a suitable tool. Break

apart the pleats and inspect the oil filter for metal
debris. An excessive amount of metal debris in
the oil filter may indicate early wear or a pending
failure. Illustration 25
g00988564

(1) Filter mounting base

Use a magnet to differentiate between the ferrous (2) Oil filter gasket
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate 3. Clean the sealing surface of the filter mounting
wear on the steel and cast iron parts of the engine. base (1). Ensure that all of the old oil filter gasket
is removed.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of 4. Apply clean engine oil to the new oil filter gasket
the engine. Parts that may be affected include (2).
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
NOTICE
Due to normal wear and friction, it is not Do not fill the oil filters with oil before installing them.
uncommon to find small amounts of debris in This oil would not be filtered and could be contaminat-
the oil filter. Consult your Perkins dealer or your ed. Contaminated oil can cause accelerated wear to
Perkins distributor in order to arrange for a further engine components.
analysis if an excessive amount of debris is found
in the oil filter. 5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil
filter.

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual for more information on
lubricant specifications. Fill the crankcase with the
proper amount of oil. Refer to the Operation and
Maintenance Manual for more information on refill
capacities.

NOTICE
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer’s recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
60
Maintenance Section
Engine Valve Lash - Inspect/Adjust

NOTICE
To prevent crankshaft bearing damage, crank the en- Ensure that the engine can not be started while
gine with the fuel OFF. This will fill the oil filters before this maintenance is being performed. To help pre-
starting the engine. Do not crank the engine for more vent possible injury, do not use the starting motor
than 30 seconds. to turn the flywheel.

2. Start the engine and run the engine at “LOW Hot engine components can cause burns. Allow
IDLE” for two minutes. Perform this procedure in additional time for the engine to cool before mea-
order to ensure that the lubrication system has suring/adjusting valve lash clearance.
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks. Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement,
3. Stop the engine and allow the oil to drain back to allow the valves to cool before this maintenance is
the sump for a minimum of ten minutes. performed.

Refer to the Service Manual for more information.

i01937717

Fuel System - Prime

g00986928
Illustration 26

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

4. Remove the oil level dipstick in order to check the
from the fuel system before the engine can be
oil level. Maintain the oil level between the “MIN”
started. Air can enter the fuel system when the
and “MAX” marks on the oil level dipstick.
following events occur:

i01937238 • The fuel tank is empty or the fuel tank has been
partially drained.
Engine Valve Lash -
Inspect/Adjust • The low pressure fuel lines are disconnected.
• A leak exists in the low pressure fuel system.

The initial valve lash adjustment on new engines, • The fuel filter is replaced.
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The Use the following procedure in order to remove air
adjustment is necessary due to the initial wear of from the fuel system:
the valve train components and to the seating of the
valve train components. 1. Turn the key switch to the RUN position. Leave
the key switch in the RUN position for 1 minutes.
This maintenance is recommended by Perkins as
part of a lubrication and preventive maintenance 2. Turn the key switch to the OFF position.
schedule in order to help provide maximum engine
life. Note: Damage to the fuel injection pump, to the
battery, and to the starter motor can occur if the
starter motor is used excessively to purge the air
NOTICE from the fuel system.
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your 3. Loosen the flare nuts for the high pressure fuel
Perkins dealer or your Perkins distributor for the com- lines on all of the fuel injection nozzles.
plete valve lash adjustment procedure.

Operation of Perkins engines with improper valve ad-

justments can reduce engine efficiency. This reduced
efficiency could result in excessive fuel usage and/or
shortened engine component life.
 61
Maintenance Section
Fuel System Filter - Replace

NOTICE
Do not crank the engine for more than 10 seconds.
Allow the starter motor to cool for 30 seconds before
cranking again.

Do not engage the starter when the flywheel is turning.

4. Observe the connection at the flare nut. Operate

the starting motor and crank the engine until the
fuel is free of air.

5. Tighten the flare nuts to a torque of 26.5 N·m

(19.5 lb ft) to 32.4 N·m (23.9 lb ft).

6. The engine is now ready to start. Operate the

engine at low idle for a minimum of five minutes
immediately after air has been removed from the
fuel system.

Note: Running the engine for this period of time will g00992025
Illustration 27
help ensure that the pump is completely free of air.
(1) Electric fuel priming pump
(2) Fuel filter base
(3) Quick release collar
i01905248
(4) Fuel filter
Fuel System Filter - Replace (5)
(6)
Sediment bowl
Drain valve for fuel filter

1. Close the fuel supply valve.

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

drain valve (6) and drain the fuel and water from
Fuel leaked or spilled onto hot surfaces or elec- fuel filter (4) into a suitable container.
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when 3. Remove sediment bowl (5).
changing fuel filters or water separator elements.
Clean up fuel spills immediately. NOTICE
Do not use a tool in order to remove the fuel filter.
NOTICE Attempting to remove the fuel filter with a filter wrench
Do not allow dirt to enter the fuel system. Thoroughly or a filter strap could damage the locking ring.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- 4. Hold fuel filter (4) and rotate quick release collar
nected fuel system component. (3) counterclockwise. Remove quick release collar
(3). The used element should be removed and
Turn the fuel supply valve to the OFF position before discarded.
performing this maintenance. Place a tray under the
fuel filter in order to catch any fuel that might spill. NOTICE
Clean up any spilled fuel immediately. Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.

5. Ensure that the fuel filter base is clean. Push a

new fuel filter fully into the fuel filter base.

6. Hold the fuel filter in place. Fit locking ring (3) into
position. Rotate the locking ring clockwise in order
to fasten the fuel filter to the fuel filter base.
62
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

7. Thoroughly clean sediment bowl (5). Inspect the 2. Close the drain valve (2).
O-ring seals. Install new O-ring seals, if necessary.
Install the sediment bowl to the new element. NOTICE
Hand tighten the sediment bowl. Hand tightening The water separator is under suction during normal
is the only method that should be used. engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
8. Prime the fuel system. Refer to Operation and system.
Maintenance Manual, “Fuel System - Prime”.

i01937818 i01938468

Fuel System Primary Fuel Tank Water and Sediment

Filter/Water Separator - Drain - Drain

NOTICE
Care must be taken to ensure that fluids are contained
Fuel leaked or spilled onto hot surfaces or elec- during performance of inspection, maintenance, test-
trical components can cause a fire. To help pre- ing, adjusting, and repair of the product. Be prepared
vent possible injury, turn the start switch off when to collect the fluid with suitable containers before
changing fuel filters or water separator elements. opening any compartment or disassembling any com-
Clean up fuel spills immediately. ponent containing fluids.

Dispose of all fluids according to local regulations and

NOTICE mandates.
The water separator is not a filter. The water separa-
tor separates water from the fuel. The engine should
never be allowed to run with the water separator more Fuel Tank
than half full. Engine damage may result.
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.

Drain the Water and the Sediment

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

Open the drain valve on the bottom of the fuel tank

in order to drain the water and the sediment. Close
the drain valve.

Check the fuel daily. Drain the water and sediment

g00992049 from the fuel tank after operating the engine or drain
Illustration 28
the water and sediment from the fuel tank after the
(1) Filter fuel tank has been filled. Allow five to ten minutes
(2) Drain
before performing this procedure.
1. Open the drain valve (2). Catch the draining water
in a suitable container. Dispose of the draining
water properly.
 63
Maintenance Section
Hoses and Clamps - Inspect/Replace

Fill the fuel tank after operating the engine in

order to drive out moist air. This will help prevent NOTICE
condensation. Do not fill the tank to the top. The Do not bend or strike high pressure lines. Do not in-
fuel expands as the fuel gets warm. The tank may stall bent or damaged lines, tubes or hoses. Repair
overflow. any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
Some fuel tanks use supply pipes that allow water and hoses carefully. Tighten all connections to the rec-
and sediment to settle below the end of the fuel ommended torque.
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular Check for the following conditions:
maintenance of the fuel system filter is important.
• End fittings that are damaged or leaking
Fuel Storage Tanks • Outer covering that is chafed or cut
Drain the water and the sediment from the fuel • Exposed wire that is used for reinforcement
storage tank during the following conditions:
• Outer covering that is ballooning locally
• Weekly
• Flexible part of the hose that is kinked or crushed
• Oil change
• Armoring that is embedded in the outer covering
• Refill of the tank
A constant torque hose clamp can be used in place
This will help prevent water or sediment from being of any standard hose clamp. Ensure that the constant
pumped from the storage tank into the engine fuel torque hose clamp is the same size as the standard
tank. clamp.
If a bulk storage tank has been refilled or moved Due to extreme temperature changes, the hose will
recently, allow adequate time for the sediment to harden. Hardening of the hoses will cause hose
settle before filling the engine fuel tank. Internal clamps to loosen. This can result in leaks. A constant
baffles in the bulk storage tank will also help trap torque hose clamp will help to prevent loose hose
sediment. Filtering fuel that is pumped from the clamps.
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. Each installation application can be different. The
differences depend on the following factors:
i01907723
• Type of hose
Hoses and Clamps -
Inspect/Replace • Type of fitting material
• Anticipated expansion and contraction of the hose

Inspect all hoses for leaks that are caused by the

• Anticipated expansion and contraction of the
fittings
following conditions:

• Cracking Replace the Hoses and the Clamps

• Softness Refer to the Disassembly and Assembly Manual, “Oil
Cooler - Remove and Oil Cooler - Install” for further
• Loose clamps information on removing and replacing the oil cooler
hoses. Refer to the Torque Specifications Manual for
Replace hoses that are cracked or soft. Tighten any further information on pipe fittings, hose clamps, and
loose clamps. constant torque hose clamps.

Refer to the OEM information for further information

on removing and replacing fuel hoses (if equipped).
64
Maintenance Section
Radiator - Clean

The coolant system and the hoses for the coolant i01907732
system are not usually supplied by Perkins. The
following text describes a typical method of replacing Radiator - Clean
coolant hoses. Refer to the OEM information for
further information on the coolant system and the
hoses for the coolant system.
The radiator is not usually supplied by Perkins. The
following text describes a typical cleaning procedure
for the radiator. Refer to the OEM information for
further information on cleaning the radiator.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, Note: Adjust the frequency of cleaning according to
stop the engine and wait until the cooling system the effects of the operating environment.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- Inspect the radiator for these items: Damaged fins,
sure. corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowly in

order to relieve any pressure. Remove the cooling Personal injury can result from air pressure.
system filler cap.
Personal injury can result without following prop-
Note: Drain the coolant into a suitable, clean er procedure. When using pressure air, wear a pro-
container. The coolant can be reused. tective face shield and protective clothing.
3. Drain the coolant from the cooling system to a Maximum air pressure at the nozzle must be less
level that is below the hose that is being replaced. than 205 kPa (30 psi) for cleaning purposes.
4. Remove the hose clamps.
Pressurized air is the preferred method for removing
5. Disconnect the old hose. loose debris. Direct the air in the opposite direction
to the fan’s air flow. Hold the nozzle approximately
6. Replace the old hose with a new hose. 6 mm (0.25 inch) away from the radiator fins. Slowly
move the air nozzle in a direction that is parallel with
Note: For torques on hose clamps, see Torque the radiator tube assembly. This will remove debris
Specifications Manual, “Torques for Standard Hose that is between the tubes.
Clamps and Torques for Constant Torque Hose
Clamps”. Also refer to the OEM information for further Pressurized water may also be used for cleaning.
information on torques for hose clamps. The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
7. Install the hose clamps with a torque wrench. water in order to soften mud. Clean the core from
both sides.
Note: For the proper coolant, see Operation and
Maintenance Manual, “General Coolant Information Use a degreaser and steam for removal of oil and
and Coolant Recommendations”. grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
8. Refill the cooling system. Refer to the OEM core with clean water.
information for further information on refilling the
cooling system. If the radiator is blocked internally, refer to the OEM
Manual for information regarding flushing the cooling
9. Clean the cooling system filler cap. Inspect the system.
cooling system filler cap’s seals. Replace the
cooling system filler cap if the seals are damaged. After cleaning, start the engine and accelerate the
Install the cooling system filler cap. engine to high idle rpm. This will help in the removal
of debris and the drying of the core. Stop the engine.
10. Start the engine. Inspect the cooling system for Use a light bulb behind the core in order to inspect
leaks. the core for cleanliness. Repeat the cleaning, if
necessary.
 65
Maintenance Section
Severe Service Application - Check

Inspect the fins for damage. Bent fins may be opened Environmental Factors
with a “comb”. Inspect these items for good condition:
Welds, mounting brackets, air lines, connections, Ambient temperatures – The engine may be
clamps, and seals. Make repairs, if necessary. exposed to extended operation in extremely
cold environments or hot environments. Valve
components can be damaged by carbon buildup if
i01907735
the engine is frequently started and stopped in very
Severe Service Application - cold temperatures. Extremely hot intake air reduces
engine performance.
Check
Quality of the air – The engine may be exposed
to extended operation in an environment that is
dirty or dusty, unless the equipment is cleaned
Severe service is the application of an engine that regularly. Mud, dirt and dust can encase components.
exceeds the current published standards for that Maintenance can be very difficult. The buildup can
engine. Perkins maintains standards for the following contain corrosive chemicals.
engine parameters:
Buildup – Compounds, elements, corrosive
• Performance such as power range, speed range, chemicals and salt can damage some components.
and fuel consumption
Altitude – Problems can arise when the engine is
• Fuel quality operated at altitudes that are higher than the intended
settings for that application. Necessary adjustments
• Operational Altitude should be made.

• Maintenance intervals Improper Operating Procedures

• Oil selection and maintenance
• Extended operation at low idle
• Coolant type and maintenance • Frequent hot shutdowns
• Environmental qualities • Operating at excessive loads
• Installation
• Operating at excessive speeds
Refer to the standards for the engine or consult your
Perkins dealer or your Perkins distributor in order to • Operating outside the intended application
determine if the engine is operating within the defined
parameters. Improper Maintenance Procedures
Severe service operation can accelerate component • Extending the maintenance intervals
wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in • Failure to use recommended fuel, lubricants and
order to ensure maximum reliability and retention of coolant/antifreeze
full service life.
i01907746
Due to individual applications, it is not possible
to identify all of the factors which can contribute
to severe service operation. Consult your Perkins
Starting Motor - Inspect
dealer or your Perkins distributor for the unique
maintenance that is necessary for the engine.
Perkins recommends a scheduled inspection of the
The operating environment, improper operating starting motor. If the starting motor fails, the engine
procedures and improper maintenance procedures may not start in an emergency situation.
can be factors which contribute to a severe service
application.
66
Maintenance Section
Turbocharger - Inspect

Check the starting motor for proper operation. Check Removal and Installation
the electrical connections and clean the electrical
connections. Refer to the Systems Operation, Testing For options regarding the removal, installation, repair
and Adjusting Manual, “Electric Starting System - and replacement, consult your Perkins dealer or
Test” for more information on the checking procedure your Perkins distributor. Refer to the Disassembly
and for specifications or consult your Perkins dealer and Assembly Manual, “Turbocharger - Remove and
or your Perkins distributor for assistance. Turbocharger - Install” for further information.

i01938674 Cleaning and Inspecting

Turbocharger - Inspect 1. Remove the pipe from the turbocharger exhaust
(If Equipped) outlet and remove the air intake pipe to the
turbocharger. Visually inspect the piping for the
presence of oil. Clean the interior of the pipes
in order to prevent dirt from entering during
reassembly.
Periodic inspection and cleaning is recommended
for the turbocharger compressor housing (inlet side).
2. Gently turn the compressor wheel and the turbine
Any fumes from the crankcase are filtered through
wheel with a finger. The assembly should turn
the air inlet system. Therefore, by-products from oil
freely. Inspect the compressor wheel and the
and from combustion can collect in the turbocharger
turbine wheel for contact with the turbocharger
compressor housing. Over time, this buildup can
housing. There should not be any visible signs of
contribute to loss of engine power, increased black
contact between the turbine wheel or compressor
smoke and overall loss of engine efficiency.
wheel and the turbocharger housing. If there is
any indication of contact between the rotating
If the turbocharger fails during engine operation,
turbine wheel or the compressor wheel and the
damage to the turbocharger compressor wheel
turbocharger housing, the turbocharger must be
and/or to the engine may occur. Damage to the
renewed.
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder
3. Check the compressor wheel for cleanliness.
head.
If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering
NOTICE system. If oil is found only on the back side of the
Turbocharger bearing failures can cause large quan- wheel, there is a possibility of a failed turbocharger
tities of oil to enter the air inlet and exhaust systems. oil seal.
Loss of engine lubricant can result in serious engine
damage. The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
Minor leakage of a turbocharger housing under ex- may also be the result of a restriction of the line
tended low idle operation should not cause problems for the inlet air (plugged air filters), which causes
as long as a turbocharger bearing failure has not oc- the turbocharger to slobber.
curred.
4. Inspect the bore of the turbine housing for
When a turbocharger bearing failure is accompanied corrosion.
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue 5. Clean the turbocharger housing with standard
engine operation until the turbocharger is repaired or shop solvents and a soft bristle brush.
replaced.
6. Replace the compressor cover. Turn the
An inspection of the turbocharger can minimize compressor gently in order to check that the
unscheduled downtime. An inspection of the compressor turns freely and does not contact
turbocharger can also reduce the chance for potential the compressor cover. Fasten the air intake pipe
damage to other engine parts. and the exhaust outlet pipe to the turbocharger
housing.
Note: Turbocharger components require precision
clearances. The turbocharger turbine and compressor
assembly must be accurately balanced due to
high operational rpm. Severe Service Applications
can accelerate component wear. Severe Service
Applications require more frequent inspections of the
compressor.
 67
Maintenance Section
Walk-Around Inspection

i01907741 • Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil
Walk-Around Inspection pan, the oil filters and the rocker cover.

• Inspect the fuel system for leaks. Look for loose

fuel line clamps and/or tie-wraps.
Inspect the Engine for Leaks and
for Loose Connections • Inspect the piping for the air intake system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
A walk-around inspection should only take a few hoses, tubes, wiring harnesses, etc.
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
• Inspect the alternator belts and any accessory
drive belts for cracks, breaks or other damage.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting Belts for multiple groove pulleys must be replaced as
the engine. Look for items such as oil leaks or coolant matched sets. If only one belt is replaced, the belt will
leaks, loose bolts, worn belts, loose connections and carry more load than the belts that are not replaced.
trash buildup. Make repairs, as needed: The older belts are stretched. The additional load on
the new belt could cause the belt to break.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
• Drain the water and the sediment from the fuel
tank on a daily basis in order to ensure that only
• Wipe all caps and plugs before the engine is clean fuel enters the fuel system.
serviced in order to reduce the chance of system
contamination.
• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
NOTICE wires.
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct • Inspect the ground strap for a good connection and
the leak. If leaking is suspected, check the fluid levels for good condition.
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be • Disconnect any battery chargers that are not
unwarranted. protected against the current drain of the starting
motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with
NOTICE
a maintenance free battery.
Accumulated grease and/or oil on an engine is a fire
hazard. Remove the accumulated grease and oil. Re-
fer to this Operation and Maintenance Manual, “En- • Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that
gine - Clean” for more information.
can not be calibrated.

• Ensure that the cooling system hoses are properly i01907756

clamped and that the cooling system hoses are
tight. Check for leaks. Check the condition of all Water Pump - Inspect
pipes.

• Inspect the water pump for coolant leaks.

A failed water pump may cause severe engine
Note: The water pump seal is lubricated by the overheating problems that could result in the following
coolant in the cooling system. It is normal for a small conditions:
amount of leakage to occur as the engine cools down
and the parts contract. • Cracks in the cylinder head
Excessive coolant leakage may indicate the need • A piston seizure
to replace the water pump seal. For the removal of
the water pump and the installation of water pump • Other potential damage to the engine
and/or seal, refer to the Disassembly and Assembly
Manual, “Water Pump - Remove and Install” for more
information or consult your Perkins dealer or your
Perkins distributor.
68
Maintenance Section
Water Pump - Inspect

Note: The water pump seal is lubricated by the

coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down
and parts contract.

Visually inspect the water pump for leaks. Renew

the water pump seal or the water pump if there
is an excessive leakage of coolant. Refer to the
Disassembly and Assembly Manual, “Water Pump
- Remove and Install” for the disassembly and
assembly procedure.
 69
Warranty Section
Warranty Information

Warranty Section

Warranty Information
i01903596

Emissions Warranty
Information

This engine may be certified to comply with exhaust

emission standards and gaseous emission standards
that are prescribed by the law at the time of
manufacture, and this engine may be covered by an
Emissions Warranty. Consult your authorized Perkins
dealer or your authorized Perkins distributor in order
to determine if your engine is emissions certified and
if your engine is subject to an Emissions Warranty.
70
Index Section

Index
A Cooling System Supplemental Coolant Additive
(SCA) - Test/Add.................................................. 55
After Starting Engine ............................................. 27 Add the SCA, If Necessary ................................ 55
After Stopping Engine............................................ 29 Test for SCA Concentration ............................... 55
Aftermarket Oil Additives ....................................... 37 Crushing Prevention and Cutting Prevention ........ 12
Alternator - Inspect ................................................ 49
Alternator and Fan Belts - Inspect/Adjust/
Replace................................................................ 49 D
Adjustment ......................................................... 49
Inspection........................................................... 49 Driven Equipment - Check..................................... 56
Replacement...................................................... 49

E
B
Electrical System ................................................... 13
Battery - Replace................................................... 50 Grounding Practices .......................................... 13
Battery Electrolyte Level - Check .......................... 50 Emergency Stopping ............................................. 29
Battery or Battery Cable - Disconnect ................... 51 Emissions Certification Film .................................. 19
Before Starting Engine .................................... 12, 25 Emissions Warranty Information............................ 69
Burn Prevention....................................................... 9 Engine - Clean....................................................... 56
Batteries............................................................. 10 Engine Air Cleaner Element (Single Element) -
Coolant................................................................. 9 Inspect/Replace ................................................... 56
Oils..................................................................... 10 Engine Air Cleaner Service Indicator - Inspect...... 57
Test the Service Indicator................................... 57
Engine Description ................................................ 18
C Engine Cooling and Lubrication ......................... 18
Engine Service Life ............................................ 18
Cold Weather Lubricants ....................................... 37 Engine Identification .............................................. 19
Cold Weather Operation........................................ 30 Engine Lifting......................................................... 21
Hints for Cold Weather Operation...................... 30 Engine Mounts - Inspect........................................ 57
Idling the Engine ................................................ 31 Engine Oil .............................................................. 34
Recommendations for Coolant Warm Up .......... 31 Commercial Oils................................................. 34
Recommendations for the Coolant .................... 30 Total Base Number (TBN) and Fuel Sulfur Levels
Viscosity of the Engine Lubrication Oil............... 30 for Direct Injection (DI) Diesel Engines ............ 35
Commercial Heavy-Duty Coolant/Antifreeze and Engine Oil and Filter - Change .............................. 58
SCA ..................................................................... 45 Drain the Engine Oil........................................... 58
Adding the SCA to Heavy-Duty Coolant at the Fill the Engine Crankcase .................................. 59
Initial Fill ........................................................... 45 Replace the Oil Filter ......................................... 59
Adding the SCA to Heavy-Duty Coolant For Engine Oil Level - Check ....................................... 58
Maintenance..................................................... 45 Engine Operation................................................... 28
Cleaning the System of Heavy-Duty Engine Starting ................................................ 12, 25
Coolant/Antifreeze ........................................... 46 Engine Stopping .............................................. 13, 29
Coolant Recommendations ................................... 42 Engine Storage...................................................... 21
Cooling System Coolant - Change (Commercial Cooling System.................................................. 22
Heavy Duty) ......................................................... 52 Exhaust System ................................................. 22
Drain .................................................................. 53 General Items .................................................... 22
Fill ...................................................................... 53 Induction System ............................................... 22
Flush .................................................................. 53 Lubrication System ............................................ 21
Cooling System Coolant (ELC) - Change.............. 51 Engine Valve Lash - Inspect/Adjust ....................... 60
Drain .................................................................. 51 Extended Life Coolant (ELC)................................. 43
Fill ...................................................................... 52 Extended Life Coolant (ELC) Cooling System
Flush .................................................................. 52 Maintenance ........................................................ 43
Cooling System Coolant Extender (ELC) - Add..... 54 Changing to Perkins ELC................................... 44
Cooling System Coolant Level - Check ................. 54 ELC Cooling System Cleaning........................... 44
Engines With a Coolant Recovery Tank............. 54 ELC Cooling System Contamination.................. 45
Engines Without a Coolant Recovery Tank........ 55 Perkins ELC Extender ....................................... 43
Cooling System Specifications .............................. 41 Proper additions to the Extended Life Coolant .. 43
 71
Index Section

F Lubricant Information............................................. 34
API Oils .............................................................. 34
Fire Prevention and Explosion Prevention ............ 10 Engine Manufacturers Association (EMA) Oils .. 34
Fire Extinguisher ................................................. 11 General Information ........................................... 34
Lines, Tubes and Hoses ..................................... 11 Lubricant Specifications......................................... 34
Foreword ................................................................. 5
California Proposition 65 Warning ....................... 5
Literature Information........................................... 4 M
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4 Maintenance Interval Schedule ............................. 48
Operation ............................................................. 4 Maintenance Section ............................................. 34
Overhaul .............................................................. 4 Model View Illustrations......................................... 14
Safety................................................................... 4 Model Views .......................................................... 14
Fuel and the Effect from Cold Weather ................. 32
Fuel Conservation Practices.................................. 28
Fuel Recommendations......................................... 38 O
Fuel Related Components in Cold Weather .......... 33
Fuel Filters ......................................................... 33 Operation Section.................................................. 21
Fuel Heaters ...................................................... 33
Fuel Tanks.......................................................... 33
Fuel Specifications ................................................ 38 P
Fuel System - Prime .............................................. 60
Fuel System Filter - Replace ................................. 61 Product Identification Information .......................... 19
Fuel System Primary Filter/Water Separator - Product Information Section .................................. 14
Drain .................................................................... 62
Fuel Tank Water and Sediment - Drain ................. 62
Drain the Water and the Sediment..................... 62 R
Fuel Storage Tanks ............................................ 63
Fuel Tank ........................................................... 62 Radiator - Clean .................................................... 64
Re-refined Base Stock Oils ................................... 37
Reference Numbers .............................................. 19
G Record for Reference......................................... 19
Refill Capacities..................................................... 47
Gauges and Indicators .......................................... 24 Cooling System.................................................. 47
General Coolant Information ................................. 41 Lubrication System ............................................ 47
Additives ............................................................ 41
Glycol ................................................................. 42
Water ................................................................. 41 S
General Hazard Information .................................... 8
Containing Fluid Spillage ..................................... 9 Safety Section ......................................................... 6
Fluid Penetration.................................................. 9 Safety Signs and Labels.......................................... 6
Pressure Air and Water........................................ 9 Serial Number Plate .............................................. 19
Severe Service Application - Check ...................... 65
Environmental Factors ....................................... 65
H Improper Maintenance Procedures.................... 65
Improper Operating Procedures ........................ 65
Hoses and Clamps - Inspect/Replace ................... 63 Starting Motor - Inspect ......................................... 65
Replace the Hoses and the Clamps .................. 63 Starting the Engine ................................................ 26
Starting with Jump Start Cables ............................ 26
Stopping the Engine .............................................. 29
I Synthetic Base Stock Oils ..................................... 36

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

T

L Table of Contents..................................................... 3
Turbocharger - Inspect (If Equipped)..................... 66
Lifting and Storage ................................................ 21 Cleaning and Inspecting .................................... 66
Removal and Installation.................................... 66
72
Index Section

Walk-Around Inspection ........................................ 67

Inspect the Engine for Leaks and for Loose
Connections ..................................................... 67
Warranty Information ............................................. 69
Warranty Section ................................................... 69
Water Pump - Inspect............................................ 67
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
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