SEBU8337-03 (en-us)

February 2023

Operation and
Maintenance
Manual
2206-E13 Industrial Engine
 i08815461

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 correctly.
Incorrect 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. You must not use
this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of
the product in the location of use, including site-specific rules and precautions applicable to the
worksite. 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 you are authorized to perform this work, and that the product will not
be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins re-
placement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury
or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8337-03 3
Table of Contents

Table of Contents Cold Weather Operation ................................. 39

Foreword ........................................................... 4 Maintenance Section

Refill Capacities............................................... 42
Safety Section
Maintenance Interval Schedule....................... 57
Safety Messages............................................... 6

General Hazard Information.............................. 7 Warranty Section

Burn Prevention............................................... 10 Warranty Information....................................... 87

Fire Prevention and Explosion Prevention.......11 Index Section

Crushing Prevention and Cutting Prevention.. 13 Index................................................................ 88

Mounting and Dismounting ............................. 13

Before Starting Engine .................................... 13

Engine Starting................................................ 13

Engine Stopping .............................................. 14

Electrical System............................................. 14

Engine Electronics........................................... 15

Product Information Section

General Information ........................................ 16

Model Views .................................................... 17

Product Identification Information ................... 20

Operation Section

Lifting and Storage .......................................... 24

Gauges and Indicators .................................... 27

Features and Controls..................................... 28

Engine Diagnostics ......................................... 33

Engine Starting................................................ 34

Engine Operation ............................................ 37

Engine Stopping .............................................. 38

4 SEBU8337-03
Foreword

Foreword Some photographs or illustrations in this manual

show details or attachments that may be different
from your engine. Guards and covers may have been
California Proposition 65 Warning removed for illustrative purposes. Continuing
improvement and advancement of product design
Diesel engine exhaust and some of its may have caused changes to your engine which are
not included in this manual. Whenever a question
constituents are known to the State of arises regarding your engine, or this manual, please
California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins
and other reproductive harm. distributor for the latest available information.

WARNING – This product can Safety

expose you to chemicals
including ethylene glycol, which This safety section lists basic safety precautions. In
is known to the State of California to addition, this section identifies hazardous, warning
cause birth defects or other reproductive situations. Read and understand the basic
precautions listed in the safety section before
harm. For more information go to: operating or performing lubrication, maintenance,
and repair on this product.
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands Operation
after handling to avoid incidental Operating techniques outlined in this manual are
ingestion. basic. The operating techniques assist with
developing the skills and techniques required to
WARNING – This product can operate the engine more efficiently and economically.
expose you to chemicals Skill and techniques develop as the operator gains
including lead and lead knowledge of the engine and the capabilities of the
compounds, which are known to the engine.
State of California to cause cancer, birth The operation section is a reference for operators.
defects, or other reproductive harm. For Photographs and illustrations guide the operator
more information go to: through procedures of inspecting, starting, operating,
and stopping the engine. This section also includes a
www.P65Warnings.ca.gov discussion of electronic diagnostic information.

Wash hands after handling components Maintenance

that may contain lead.
The maintenance section is a guide to engine care.
Literature Information The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
This manual contains safety, operation instructions, intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
lubrication, and maintenance information. This
manual should be stored in or near the engine area in Recommended service should be performed at the
a literature holder or literature storage area. Read, appropriate intervals as indicated in the Maintenance
study, and keep the manual with the literature and Interval Schedule. The actual operating environment
engine information. of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
English is the primary language for all Perkins freezing cold operating conditions, more frequent
publications. The English used facilitates translation lubrication, and maintenance than is specified in the
and consistency. Maintenance Interval Schedule may be necessary.
SEBU8337-03 5
Foreword

The maintenance schedule items are organized for a

preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.

Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. Perkins recommends that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
Perkins also recommends that a maintenance record
be maintained as part of the permanent record of the
engine.
Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
authorized Perkins distributor or dealer. Your Perkins
dealer or your Perkins distributor offers various
options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available.
Consult with your Perkins dealer or your Perkins
distributor for information regarding these options.
6 SEBU8337-03
Safety Section
Safety Messages

Safety Section
i02767956

Safety Messages

Illustration 1 g01384682
Location of safety message

There may be several specific safety messages on Universal Warning (1)

your engine. The exact location and a description of
the safety messages are reviewed in this section. The safety message for the universal warning is
Please become familiar with all safety messages. located on both sides of the valve cover base.
Ensure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and
soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off of
the engine.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Perkins
distributor can provide new safety messages.
SEBU8337-03 7
Safety Section
General Hazard Information

Illustration 2 g00934493 Illustration 4 g00702020

Wear a hard hat, protective glasses, and other

protective equipment, as required.
Do not operate or work on this equipment unless Do not wear loose clothing or jewelry that can snag
you have read and understand the instructions on controls or on other parts of the engine.
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or Make sure that all protective guards and all covers
heed the warnings could result in serious injury are secured in place on the engine.
or death.
Keep the engine free from foreign material. Remove
debris, oil, tools, and other items from the deck, from
i08312758
walkways, and from steps.
Never put maintenance fluids into glass containers.
General Hazard Information Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care.
Report all necessary repairs.
Do not allow unauthorized personnel on the
equipment.
Disconnect the batteries when maintenance is
performed or when the electrical system is serviced.
Disconnect the battery ground leads. Tape the leads
to help prevent sparks. If equipped, allow the diesel
exhaust fluid to be purged before disconnecting the
battery.
Perform maintenance on the engine with the
equipment in the servicing position. Refer to the OEM
Illustration 3 g00104545
information for the procedure for placing the
equipment in the servicing position.
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that is
before you service the equipment or before you
damaged or repair the equipment.
repair the equipment.
For initial start-up of a new engine or for starting an
engine that has been serviced, make provisions to
stop the engine if an overspeed occurs. The stopping
of the engine may be accomplished by shutting off
the fuel supply and/or the air supply to the engine.
Ensure that only the fuel supply line is shut off.
Ensure that the fuel return line is open.
8 SEBU8337-03
Safety Section
General Hazard Information

Start the engine from the operators station (cab).

Never short across the starting motor terminals or the
batteries. This action could bypass the engine neutral
start system and/or the electrical system could be
damaged.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a ventilated area. If
the engine is in an enclosed area, vent the engine
exhaust to the outside.
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last
two bolts or nuts, pry the cover loose to relieve any Illustration 5 g00687600
spring pressure or other pressure.
Always use a board or cardboard when you check for
Pressure Air and Water a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
Pressurized air and/or water can cause debris and/or serious injury and possible death. A pin hole leak can
hot water to be blown out. This action could result in cause severe injury. If fluid is injected into your skin,
personal injury. you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
The direct application of pressurized air or
pressurized water to the body could result in personal
injury. Containing Fluid Spillage
When pressurized air and/or water is used for Care must be taken to ensure that fluids are
cleaning, wear protective clothing, protective shoes, contained during performance of inspection,
and eye protection. Eye protection includes goggles maintenance, testing, adjusting, and repair of the
or a protective face shield. engine. Make provision to collect the fluid with a
suitable container before any compartment is opened
The maximum air pressure for cleaning purposes or before any component is disassembled.
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below • Only use the tools that are suitable for collecting
275 kPa (40 psi). fluids and equipment that is suitable for collecting
fluids.
Fluid Penetration • Only use the tools that are suitable for containing
Pressure can be trapped in the hydraulic circuit long fluids and equipment that is suitable for containing
after the engine has been stopped. The pressure can fluids.
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
information for any procedures that are required to
relieve the hydraulic pressure.
SEBU8337-03 9
Safety Section
General Hazard Information

Obey all local regulations for the disposal of liquids. Hexavalent Chromium
Perkins equipment and replacement parts comply
Static Electricity Hazard when with applicable regulations and requirements where
Fueling with Ultra-low Sulfur Diesel originally sold. Perkins recommends the use of only
genuine Perkins replacement parts.
Fuel
Hexavalent chromium has occasionally been
The removal of sulfur and other compounds in ultra- detected on exhaust and heat shield systems on
low sulfur diesel fuel (ULSD fuel) decreases the Perkins engines. Although laboratory testing is the
conductivity of ULSD and increases the ability of only accurate way to know if hexavalent chromium is,
ULSD to store static charge. Refineries may have in fact, present, the presence of a yellow deposit in
treated the fuel with a static dissipating additive. areas of high heat (for example, exhaust system
Many factors can reduce the effectiveness of the components or exhaust insulation) may be an
additive over time. Static charges can build up in indication of the presence of hexavalent chromium.
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when Use caution if you suspect the presence of
combustible vapors are present could result in a fire hexavalent chromium. Avoid skin contact when
or explosion. Ensure that the entire system used to handling items that you suspect may contain
refuel your machine (fuel supply tank, transfer pump, hexavalent chromium, and avoid inhalation of any
transfer hose, nozzle, and others) is properly dust in the suspect area. Inhalation of, or skin contact
grounded and bonded. Consult with your fuel or fuel with, hexavalent chromium dust may be hazardous to
system supplier to ensure that the delivery system your health.
complies with fueling standards for proper grounding
and bonding. If such yellow deposits are found on the engine,
engine component parts, or associated equipment or
packages, Perkins recommends following local
health and safety regulations and guidelines, utilizing
good hygiene, and adhering to safe work practices
Avoid static electricity risk when fueling. Ultra- when handling the equipment or parts. Perkins also
low sulfur diesel fuel (ULSD fuel) poses a greater recommends the following:
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death • Wear appropriate Personal Protective Equipment
or serious injury from fire or explosion. Consult (PPE)
with your fuel or fuel system supplier to ensure
the delivery system is in compliance with fueling • Wash your hands and face with soap and water
standards for proper grounding and bonding prior to eating, drinking, or smoking, and also
practices. during rest room breaks, to prevent ingestion of
any yellow powder

Inhalation • Never use compressed air for cleaning areas

suspected of containing hexavalent chromium
• Avoid brushing, grinding, or cutting materials
suspected of containing hexavalent chromium
• Obey environmental regulations for the disposal of
all materials that may contain or have come into
contact with hexavalent chromium
• Stay away from areas that might have hexavalent
chromium particles in the air.

Asbestos Information
Perkins equipment and replacement parts that are
shipped from Perkins engine company limited are
asbestos free. Perkins recommends the use of only
Illustration 6 g00702022 genuine Perkins replacement parts. Use the following
guidelines when you handle any replacement parts
Exhaust that contain asbestos or when you handle asbestos
debris.
Use caution. Exhaust fumes can be hazardous to
health. If you operate the equipment in an enclosed
area, adequate ventilation is necessary.
10 SEBU8337-03
Safety Section
Burn Prevention

Use caution. Avoid inhaling dust that might be Dispose of Waste Properly
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos. Illustration 7 g00706404

• Use a wet method to clean up asbestos materials. Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
• A vacuum cleaner that is equipped with a high disposed of in accordance with local regulations.
efficiency particulate air filter (HEPA) can also be
used. Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
• Use exhaust ventilation on permanent machining drain, or into any source of water.
jobs.
i08159513
• Wear an approved respirator if there is no other
way to control the dust.
Burn Prevention
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration Do not touch any part of an operating engine. Allow
(OSHA) requirements. These OSHA requirements the engine to cool before any maintenance is
can be found in “29 CFR 1910.1001”. performed on the engine. Relieve all pressure in the
appropriate system before any lines, fittings, or
• Obey environmental regulations for the disposal of related items are disconnected.
asbestos.

• Stay away from areas that might have asbestos Coolant

particles in the air. 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 that the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly to
relieve pressure.
SEBU8337-03 11
Safety Section
Fire Prevention and Explosion Prevention

Cooling system conditioner contains alkali. Alkali can Determine whether the engine will be operated in an
cause personal injury. Do not allow alkali to contact environment that allows combustible gases to be
the skin, the eyes, or the mouth. drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
Oils property damage, or engine damage could result.
If the application involves the presence of
Hot oil and hot lubricating components can cause
combustible gases, consult your Perkins dealer and/
personal injury. Do not allow hot oil or hot
components to contact the skin. or your Perkins distributor for additional information
about suitable protection devices.
If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped. Remove all flammable combustible materials or
conductive materials such as fuel, oil, and debris
The filler cap must be cool to the touch. from the engine. Do not allow any flammable
combustible materials or conductive materials to
Batteries accumulate on the engine.

The liquid in a battery is an electrolyte. Electrolyte is Store fuels and lubricants in correctly marked
an acid that can cause personal injury. Do not allow containers away from unauthorized persons. Store
electrolyte to contact the skin or the eyes. oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
Do not smoke while checking the battery electrolyte storing flammable materials.
levels. Batteries give off flammable fumes which can
explode. Do not expose the engine to any flame.

Always wear protective glasses when you work with Exhaust shields (if equipped) protect hot exhaust
batteries. Wash hands after touching batteries. The components from oil or fuel spray in case of a line, a
use of gloves is recommended. tube, or a seal failure. Exhaust shields must be
installed correctly.
i07188311 Do not weld on lines or tanks that contain flammable
fluids. Do not flame-cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
Fire Prevention and Explosion thoroughly with a nonflammable solvent prior to
Prevention welding or flame cutting.
Wiring must be kept in good condition. Ensure that all
electrical wires are correctly installed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
Illustration 8 g00704000
deterioration. The hoses must be correctly routed.
The lines and hoses must have adequate support
All fuels, most lubricants, and some coolant mixtures and secure clamps. Tighten all connections to the
are flammable. recommended torque. Leaks can cause fires.

Flammable fluids that are leaking or spilled onto hot Oil filters and fuel filters must be correctly installed.
surfaces or onto electrical components can cause a The filter housings must be tightened to the correct
fire. Fire may cause personal injury and property torque.
damage.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an
emergency shutdown.
12 SEBU8337-03
Safety Section
Fire Prevention and Explosion Prevention

Incorrect jumper cable connections can cause an

explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This action 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.

Ether
Illustration 9 g00704059
Ether is flammable and poisonous.
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not Do not smoke while you are replacing an ether
refuel an engine near open flames or sparks. Always cylinder or while you are using an ether spray.
stop the engine before refueling. Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49° C
(120° F). Keep ether cylinders away from open
flames or sparks.

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent
or damaged. Do not clip any other items to the high-
pressure lines.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Perkins dealer or your
Perkins distributor for repair or for replacement parts.
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
Illustration 10 g00704135
are present:

Gases from a battery can explode. Keep any open • End fittings are damaged or leaking.
flames or sparks away from the top of a battery. Do • Outer coverings are chafed or cut.
not smoke in battery charging areas.
Never check the battery charge by placing a metal • Wires are exposed.
object across the terminal posts. Use a voltmeter or a • Outer coverings are ballooning.
hydrometer.
• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

SEBU8337-03 13
Safety Section
Crushing Prevention and Cutting Prevention

• End fittings are displaced. i05874054

Make sure that all clamps, guards, and heat shields

are installed correctly. During engine operation,
Before Starting Engine
correct installation will help to prevent vibration,
rubbing against other parts, and excessive heat.
NOTICE
i08162291 For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
Crushing Prevention and provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
Cutting Prevention air and/or fuel supply to the engine.

Support the component properly when work beneath

the component is performed.
Engine exhaust contains products of combustion
Unless other maintenance instructions are provided, which may be harmful to your health. Always
never attempt adjustments while the engine is start and operate the engine in a well ventilated
running.
area and, if in an enclosed area, vent the exhaust
to the outside.
Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is Inspect the engine for potential hazards.
performed. After the maintenance is performed,
reinstall the guards. Do not start the engine or move any of the controls if
there is a “DO NOT OPERATE” warning tag or similar
Keep objects away from moving fan blades. The fan warning tag attached to the start switch or to the
blades will throw objects or cut objects. controls.
When objects are struck, wear protective glasses to Before starting the engine, ensure that no one is on,
avoid injury to the eyes. underneath, or close to the engine. Ensure that the
area is free of personnel.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no If equipped, ensure that the lighting system for the
one will be injured by flying debris. engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
i08159517
All protective guards and all protective covers must
Mounting and Dismounting be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean Do not bypass the automatic shutoff circuits. Do not
and keep these items in good repair. disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
Mount the engine and dismount the engine only at circuits are also provided in order to help prevent
locations that have steps and/or handholds. Do not engine damage.
climb on the engine, and do not jump off the engine.
See the Service Manual for repairs and for
Face the engine to mount the engine or dismount the adjustments.
engine. With your feet and hands, always maintain a
three-point contact with the steps and designated i07828827
handholds. Do not use any controls as handholds.
Do not stand on components which cannot support Engine Starting
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand Do not use aerosol types of starting aids such as
line to raise and lower tools or supplies. ether. Such use could result in an explosion and
personal injury.
14 SEBU8337-03
Safety Section
Engine Stopping

Use the Emergency Stop Button (if equipped) ONLY

in an emergency situation. Do not use the
Engine exhaust contains products of combustion Emergency Stop Button for normal engine stopping.
which may be harmful to your health. Always After an emergency stop, DO NOT start the engine
start and operate the engine in a well ventilated until the problem that caused the emergency stop
area and, if in an enclosed area, vent the exhaust has been corrected.
to the outside. Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
If a warning tag is attached to the engine start switch engine that has been overhauled. This may be
or to the controls, DO NOT start the engine or move accomplished by shutting off the fuel supply to the
the controls. Consult with the person that attached engine and/or shutting off the air supply to the
the warning tag before the engine is started. engine.
All protective guards and all protective covers must To stop an electronically controlled engine, cut the
be installed if the engine must be started to perform power to the engine.
service procedures. To help prevent an accident that
is caused by parts in rotation, work around the parts
carefully. i02814681

Start the engine from the operator's compartment or Electrical System

from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance Never disconnect any charging unit circuit or battery
Manual, “Engine Starting” topic in the Operation circuit cable from the battery when the charging unit
Section. Knowing the correct procedure will help to is operating. A spark can cause the combustible
prevent major damage to the engine components. gases that are produced by some batteries to ignite.
Knowing the procedure will also help to prevent
personal injury. To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
To ensure that the jacket water heater (if equipped) is negative “−” cable should be connected last from the
working correctly, check the water temperature external power source to the negative “−” terminal of
gauge and/or the oil temperature gauge during the the starting motor. If the starting motor is not
heater operation. equipped with a negative “−” terminal, connect the
cable to the engine block.
Note: The engine may be equipped with a device for
cold starting. If the engine will be operated in very Check the electrical wires daily for wires that are
cold conditions, then an extra cold starting aid may loose or frayed. Tighten all loose electrical
be required. Normally, the engine will be equipped connections before the engine is started. Repair all
frayed electrical wires before the engine is started.
with the correct type of starting aid for your region of
See the Operation and Maintenance Manual for
operation. specific starting instructions.
i09160524

Engine Stopping

• Remove the load in increments.

• Open the circuit breaker.

• Allow the engine to run for five minutes to cool.

• Stop the engine.

• Ensure 24V is supplied to the dosing cabinet for at
least 120 seconds after engine shutdown (engines
equipped with SCR systems only).
SEBU8337-03 15
Safety Section
Engine Electronics

Grounding Practice The power supply connections and the ground

connections for the engine electronics should always
be from the isolator to the battery.

i02773399

Engine Electronics

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.

This engine has a comprehensive, programmable

Engine Monitoring System. The Engine Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine
Illustration 11 g01403749
monitoring control: WARNING, ACTION ALERT and
Typical example SHUTDOWN.
(1) Starting motor to engine block
(2) Starting motor to battery negative Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring
Correct grounding for the engine electrical system is functions. The following parameters can be
necessary for optimum engine performance and monitored as a part of the Engine Monitoring System:
reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable • Atmospheric Pressure
electrical circuit paths.
• Intake Manifold Air Pressure
Uncontrolled electrical circuit paths can result in
damage to the crankshaft bearing journal surfaces • Coolant Temperature
and to aluminum components.
• Engine Oil Pressure
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical • Crankshaft Position
discharge.
• Camshaft Position
To ensure that the engine and the engine electrical
systems function correctly, an engine-to-frame • Fuel Temperature
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct • Intake Manifold Temperature
engine ground to the frame.
• System Voltage
The connections for the grounds should be tight and
free of corrosion. The engine alternator must be The Engine Monitoring package can vary for different
grounded to the negative “-” battery terminal with a engine models and different engine applications.
wire that is adequate to handle the full charging However, the monitoring system and the engine
current of the alternator. monitoring control will be similar for all engines.
16 SEBU8337-03
Product Information Section
General Information

Product Information
Section

General Information
i01889424

Welding on Engines with

Electronic Controls

NOTICE
Proper welding procedures are necessary in order to
avoid damage to the engine's ECM, sensors, and as-
sociated components. When possible, remove the
component from the unit and then weld the compo-
nent. If removal of the component is not possible, the
following procedure must be followed when you weld
with a unit that is equipped with an Electronic Engine. Illustration 12 g00765012
The following procedure is considered to be the saf- Use the example above. The current flow from the
est procedure to weld a component. This procedure welder to the ground clamp of the welder will not
should provide a minimum risk of damage to elec- cause damage to any associated components.
tronic components. (1) Engine
(2) Welding rod
(3) Keyswitch in the OFF position
NOTICE (4) Battery disconnect switch in the open position
Do not ground the welder to electrical components (5) Disconnected battery cables
(6) Battery
such as the ECM or sensors. Improper grounding (7) Electrical/Electronic component
can cause damage to the drive train bearings, hy- (8) Maximum distance between the component that is being
draulic components, electrical components, and oth- welded and any electrical/electronic component
er components. (9) The component that is being welded
(10) Current path of the welder
Clamp the ground cable from the welder to the com- (11) Ground clamp for the welder
ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos- 4. Connect the welding ground cable directly to the
sibility of damage. part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
1. Stop the engine. Turn the switched power to the possibility of welding current damage to bearings,
OFF position. hydraulic components, electrical components, and
ground straps.
2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided, Note: If electrical/electronic components are used as
open the switch. a ground for the welder, or electrical/electronic
components are located between the welder ground
3. Disconnect the J1/P1 connectors from the ECM. and the weld, current flow from the welder could
Move the harness to a position that will not allow severely damage the component.
the harness to accidentally move back and make
contact with any of the ECM pins. 5. Protect the wiring harness from welding debris and
spatter.
6. Use standard welding practices to weld the
materials.
SEBU8337-03 17
Product Information Section
Model Views

Model Views
i02770579

Model View Illustrations

Illustration 13 g01385634
Typical example
Left side engine view
(1) Connection for the breather (4) Secondary fuel filter (7) Crankshaft damper
(2) Electronic control module (ECM) (5) Primary fuel filter (8) Oil filler
(3) Fuel priming pump (6) Fuel pump
18 SEBU8337-03
Product Information Section
Engine Description

Illustration 14 g01385635
Typical example
Right side engine view
(9) Water temperature regulator housing (12) Turbocharger (15) Oil cooler
(10) Alternator (13) Oil filter (16) Exhaust manifold
(11) Water pump (14) Oil drain plug

i02770677 The electronic engines that are covered by this

manual have the following characteristics: direct fuel
Engine Description injection, electronic unit injection that is mechanically
actuated, turbocharged and air-to-air aftercooled
(ATAAC).
Table 1 The electronic engine control system provides the
2206 Engine Specifications following functions: electronic governing, automatic
air to fuel ratio control, injection timing control and
Cylinders and Arrangement In-line six cylinder system diagnostics.
Bore 130 mm (5.2 inch) An electronic governor controls the output of the unit
Stroke 157 mm (6.2 inch) injectors in order to maintain the engine rpm that is
desired.
Displacement 12.5 L (763 in3)

Firing Order 1-5-3-6-2-4

Rotation (flywheel end) Counterclockwise

SEBU8337-03 19
Product Information Section
Engine Description

Very high injection pressures are produced by Aftermarket Products and Perkins
electronically controlled, mechanically actuated unit
injectors. The injectors combine the pumping and the Engines
electronic fuel metering (duration and timing) during
injection. The unit injectors accurately control smoke When auxiliary devices, accessories, or
limiting, white smoke, and engine acceleration rates. consumables (filters, additives, catalysts, etc) which
are made by other manufacturers are used on
There is one unit injector per cylinder. Individual unit Perkins products, the Perkins warranty is not affected
injectors meter the fuel. The individual unit injectors simply because of such use.
also pump the fuel. The metering and the pumping is
done under high pressure. High injection pressures However, failures that result from the installation
help to reduce fuel consumption and emissions. The or use of other manufacturers' devices,
accessories, or consumables are NOT Perkins
use of this type of unit injector provides total defects. Therefore, the defects are NOT covered
electronic control of injection timing. The injection under the Perkins warranty.
timing varies with engine operating conditions. The
engine performance is optimized in the following
areas:
• Starting

• Emissions
• Noise

• Fuel consumption
The timing advance is achieved through precise
control of the injector firing. Engine speed is
controlled by adjusting the firing duration. The
information is provided to the Electronic Control
Module (ECM) by the crankshaft position sensor and
the camshaft position sensor. The information is for
detection of cylinder position and engine speed.
The engines have built-in diagnostics in order to
ensure that all of the components are functioning and
operating properly. In the event of a system
component deviation from the programmed limits, the
operator will be alerted to the condition by a
DIAGNOSTIC lamp that is mounted on the control
panel. An electronic service tool that is provided by
Perkins may be used to read the diagnostic codes.
These codes are logged and stored in the ECM.
Refer to Operation and Maintenance Manual,
“Engine Diagnostics” for additional information.
The cooling system consists of the following items: a
centrifugal pump that is driven by a gear, water
temperature regulator, an oil cooler and a radiator
that incorporates a shunt system.
The engine lubricating oil is supplied by a gear type
pump. The engine lubricating oil is cooled and
filtered. Bypass valves provide unrestricted flow of
lubrication oil to the engine parts when the oil
viscosity is high or if either the oil cooler or the oil
filter elements (paper cartridge) become plugged.
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper
operation and maintenance recommendations. This
includes the use of recommended fuels, coolants and
lubrication oils.
20 SEBU8337-03
Product Information Section
Product Identification Information

Product Identification
Information
i02770689

Plate Locations and Film

Locations

Illustration 15 g01385686

(1) Serial number plate

Perkins engines are identified by serial numbers.

These numbers are shown on the engine serial
number plate. Perkins distributors need these
numbers in order to determine the components that
were included with the engine. This permits accurate
identification of replacement part numbers.
SEBU8337-03 21
Product Information Section
Reference Numbers

Serial Number Plate (1) Total Cooling System Capacity

Air Cleaner Element
Fan Drive Belt

Illustration 16 g01403841
Typical example

The engine serial number plate is located on the right

side of the engine block.
Engine serial number
Designation
Engine Rating

i02563635

Reference Numbers

Information for the following items may be needed to

order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a copy of this list for a record. Keep the
information for future reference.

Record for Reference

Engine Model
Engine Serial number
Engine rpm
Primary Fuel Filter
Secondary Fuel Filter Element
Lubrication Oil Filter Element
Total Lubrication System Capacity
22 SEBU8337-03
Product Information Section
Emissions Certification Film

Alternator Belt

i02770895

Emissions Certification Film

Illustration 17 g01385765
Typical example

The emission certification film is located on the left Programmable Monitoring System
hand side of the valve mechanism cover.
(PMS)
i02817239
The Programmable Monitoring System determines
the level of action that is taken by the ECM in
Customer Specified response to a condition that can damage the engine.
Parameters These conditions are identified by the ECM from the
signals that are produced from the following sensors.

• Inlet Manifold Temperature Sensor

To record programmed specifications, use the
following blanks. • Coolant Temperature Sensor
Customer Passwords (If required). • Engine Oil Pressure Sensor
• First Password • Engine Crankshaft/Camshaft Sensors
• Second Password • Inlet Manifold Pressure Sensor
Rating Selection (L-N) • Fuel Temperature Sensor
Equipment ID

Table 2
Event Code Parameter State Trip Point Delay Time

E162 High Boost Pressure

(continued)
SEBU8337-03 23
Product Information Section
Customer Specified Parameters

(Table 2, contd)
-1 Warn Operator (1) On 300 kPa (43.5 psi) 60 seconds

-2 Action Alert (2) Always On Map 5 seconds

E360 Low Engine Oil Pressure

-1 Warn Operator (1) On 200 kPa (29 psi) 60 seconds

-2 Action Alert (2) Always On Map 2 seconds

-3 Engine Shutdown (3) Always On Map 2 seconds

E361 High Engine Coolant Temperature

-1 Warn Operator (1) On 104 °C (2190 °F) 60 seconds

-2 Action Alert (2) Always On 105 °C (221 °F) 10 seconds

-3 Engine Shutdown (3) Always On 108 °C (226 °F) 10 seconds

E362 Engine Overspeed

-1 Warn Operator (1) On 2000 RPM 1 second

-2 Action Alert (2) Always On 2050 RPM 0 second

-3 Engine Shutdown (3) Always On 2140 RPM 0 second

E363 High Fuel Supply Temperature

-1 Warn Operator (1) On 60 °C (140 °F) 60 seconds

-2 Action Alert (2) Always On 68 °C (154 °F) 60 seconds

E368 High Engine Intake Manifold Air Temperature

-1 Warn Operator (1) On 75 °C (167 °F) 60 seconds

-2 Action Alert (2) Always On 78 °C (172 °F) 10 seconds

Refer to Troubleshooting , “System Configuration

Parameters” for additional information for the
Programmable Monitoring System.
24 SEBU8337-03
Operation Section
Lifting and Storage

Operation Section i09711071

Product Storage
Lifting and Storage
Your Perkins distributor can assist in preparing the
i07444135 engine for extended storage periods.

Product Lifting An engine can be stored for up to 6 months provided

all the recommendation are adhered to.

Engine
1. Clean the engine of any dirt, rust, grease, and oil.
Inspect the exterior. Paint areas that contain paint
damage with a good quality paint.
2. Remove dirt from the air cleaners. Check all seals,
gaskets, and the filter element for damage.
3. Apply lubricant to all points in this Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
4. Drain the crankcase oil. Replace the crankcase oil
and change the oil filters. For the proper
procedure, refer to this Operation and
Illustration 18 g00103219 Maintenance Manual.
5. Add VCI oil to the crankcase oil. The volume of
NOTICE VCI oil in the crankcase oil should be 3 to 4
Always inspect lifting eyebolts and all other lifting
equipment for damage before performing any lifting. percent.
Never Bend the eyebolts and the brackets. Never
perform product lifting if the components are dam- Note: If the engine crankcase is full, drain enough
aged. Remember that the capacity of an eyebolt is engine oil so the mixture can be added.
less as the angle between the supporting members
and the object becomes less than 90 degrees. 6. Remove the air filter elements. Turn the engine at
cranking speed with the throttle control in FUEL
When it is necessary to remove a component at an OFF position. Use a sprayer to add a mixture of 50
angle, only use a link bracket that is properly rated for percent VCI oil and 50 percent engine oil into the
the weight.
air inlet or turbocharger inlet.
Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the engine. All Note: The mixture of VCI oil can be added to the inlet
supporting members (chains and cables) should be by removing the plug for checking turbocharger boost
parallel to each other. The chains and cables should pressure. The minimum application rate for the VCI
be perpendicular to the top of the object that is being oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of
lifted. engine displacement.
Some removals require lifting the fixtures to obtain 7. Use a sprayer to apply a mixture of 50 percent VCI
proper balance and safety. oil and 50 percent crankcase oil into the exhaust
To remove the engine ONLY, use the lifting eyes that openings. The minimum application rate for the oil
are on the engine. mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement. Seal the exhaust pipe and
Lifting eyes are designed and installed for specific seal any drain holes in the muffler.
engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting 8. Remove the fuel from the secondary fuel filter
fixtures obsolete. If alterations are made, ensure that housing. Alternately, empty and reinstall the spin-
proper lifting devices are provided. Consult your on fuel filter element to remove any dirt and water.
Perkins dealer for information regarding fixtures for
Drain any sleeve metering fuel pump.
proper engine lifting.
SEBU8337-03 25
Operation Section
Product Storage

Clean the primary fuel filter. Fill with calibration Disconnect the battery terminals. Place a plastic
fluid or kerosene. Install the primary fuel filter and cover over the batteries.
operate the priming pump. This procedure will
13. Remove the drive belts from the engine
send clean oil to the secondary filter and the
engine. 14. Place a waterproof cover over the engine. Ensure
that the engine cover is secure. The cover should
Open the fuel tank drain valve to drain any water
be loose enough to allow air to circulate around
and dirt from the fuel tank. Apply a spray of
the engine to prevent damage from condensation.
calibration fluid or kerosene at the rate of
30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank 15. Attach a tag with the storage date to the engine.
capacity to prevent rust in the fuel tank. Add
16. Remove the waterproof cover at 2 month or 3
0.15 mL per L (.02 oz per 1 gal US) of commercial
month intervals to check the engine for corrosion.
biocide such as Biobor JF to the fuel.
If the engine has signs of corrosion, repeat the
Apply a small amount of oil to the threads on the protection procedure.
fuel tank filler neck and install the cap. Seal all
openings to the tank to prevent evaporation of the Coolant System
fuel and as a preservative.
Completely fill the cooling system before storage.
9. Remove the fuel injectors. Apply 30 mL (1 oz) of
the mixture of oils (50 percent VCI oil and 50 Refer to this Operation and Maintenance Manual,
percent engine oil) into each cylinder. “Fluid Recommendations” for more information about
coolants.
Use a bar or a turning tool to turn over the engine
slowly. This procedure puts the oil on the cylinder Remove Engine from Storage
walls. Install all fuel injectors and tighten to the
correct torque. Refer to Disassembly and 1. Remove all outside protective covers.
Assembly Manual for more information. 2. Change the oil and filters.
10. Spray a thin amount of a mixture of 50 percent 3. Check the condition of the fan and alternator belts.
VCI oil and 50 percent engine oil onto the following Replace the belts, if necessary. Refer to this
components: flywheel, ring gear teeth, and starter Operation and Maintenance Manual, “Belts -
pinion. Install the covers to prevent evaporation of Inspect/Adjust/Replace” for the correct procedure.
the vapors from the VCI oil.
4. Replace the fuel filter elements.
11. Apply a heavy amount of Multipurpose Grease to
all outside parts that move, such as rod threads, 5. Remove the plastic covers from the air cleaner
ball joints, linkage. elements.

Note: Install all covers. Ensure that tape has been 6. Use a bar or a turning tool to turn the engine in the
installed over all openings, air inlets, exhaust normal direction of rotation. The procedure
openings, the flywheel housing, the crankcase ensures that no hydraulic locks or resistance exist.
breathers, the dipstick tubes. 7. Before starting the engine, remove the valve cover
Ensure that all covers are airtight and or covers. Put a large amount of engine oil on the
weatherproof. Use a waterproof weather resistant camshaft, cam followers, and valve mechanism to
tape such as Kendall No. 231 or an equivalent. Do prevent damage to the mechanism.
not use duct tape. Duct tape will only seal for a
short time.
12. Under most conditions, removing the batteries is
the best procedure. As an alternative, place the
batteries in storage. As needed, periodically
charge the batteries while the batteries are in
storage.
If the batteries are not removed, wash the tops of
the batteries until the tops are clean. Apply an
electrical charge to the batteries to obtain a
specific gravity of 1.225.
26 SEBU8337-03
Operation Section
Product Storage

11. Ensure that the cooling system is clean. Ensure

that the system is full. Ensure that the system has
the correct amount of supplemental cooling
system conditioner.
12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.

Illustration 19 g07564010
Typical example
(1) Plugs

8. If an engine is stored for more than 1 year, Perkins

recommends Pre lubrication of the engine to avoid
dry starting. Use a suitable pump to put engine oil
into the engine oil system.
The pump will need to create a minimum pressure
within the engine of 0.25 bar (3.6 psi). This
pressure is needed for 15 seconds to lubricate the
internal surfaces.
Remove of the plug shown in illustration 19 to
connect to the engine oil system. The connection
required is 9/16" x 18 tpi. Ensure that the correct
oil specification is used, refer to this Operation and
Maintenance Manual, “Fluid Recommendations”
for more information. After the engine internal
surfaces have been lubricated, remove connector
and install plug (1). Tighten plug to a torque of
30 N·m (265 lb in). Perkins recommends that the
procedure must be performed in a minimum
ambient temperature of 10° C (50° F).
9. Check the condition of all rubber hoses. Replace
any worn hoses. Replace any damaged hoses.
10. Before start-up, test the cooling system for a 3
percent to a 6 percent concentration of coolant
conditioner. Add liquid coolant conditioner or a
coolant conditioner element, if equipped.
Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.
Prime the engine with clean diesel fuel before
starting.
SEBU8337-03 27
Operation Section
Gauges and Indicators

Gauges and Indicators

i02773410

Gauges and Indicators

Your engine may not have the same gauges or all of

the gauges that are described. For more information
about the gauge package, see the OEM information.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time.
Noticeable changes in gauge readings indicate
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the readings are within specifications.
Determine and correct the cause of any significant
change in the readings. Consult your Perkins
distributor for assistance.

NOTICE
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result.

Engine Oil Pressure – The range for the

engine oil pressure is 420 kPa (61 psi).

Jacket Water Coolant Temperature –

Typical water temperature into the
engine is 88 °C (190 °F). Higher
temperatures may occur under certain
conditions. The water temperature reading may
vary according to load. The reading should never
exceed 107 °C (224 °F).

1. A high water temperature switch is installed in the

cooling system.
Tachometer – This gauge indicates
engine speed (rpm).

Ammeter – This gauge indicates the

amount of charge or discharge in the
battery charging circuit. Operation of
the indicator should be to the right side of “ 0””
(zero).
Service Hour Meter – The gauge
indicates operating hours of the engine.
28 SEBU8337-03
Operation Section
Features and Controls

Features and Controls If the engine is in the Warning condition, then the
event will be logged in the memory of the ECM. A
event code will be transmitted over the Perkins Data
i02780670 link and the hard wired Warning output will be
energized. If the engine is in the Warning condition,
Monitoring System the event code and output will remain while the
condition exists. The electronic service tool is used to
remove the event code from the memory of the ECM.
The trip point for the Warning alarm will be set to a
The engine has protection in three stages: factory default in production. The electronic service
tool may be used to alter the trip point for a Warning
• Warning within predefined limits.
• Action Alert
Action Alert
• Shutdown
The Action Alert informs the OEM that the engine is
The engine protection may be overridden by the approaching a critical condition. The engine should
critical condition mode. be stopped in a controlled manner. Further running of
the engine may result in an immediate shutdown.
The Electronic Control Module (ECM) monitors the
following parameters: If the engine is in the Action Alert condition, the event
will be logged in the memory of the ECM. A event
• Engine Temperatures code will be transmitted over the Perkins Data link
and the hard wired Action Alert will be energized. If
• Engine Pressures the engine is in the Action Alert condition the event
code and output will remain while the condition
• Engine Speed exists. The event code can not be cleared from the
memory of the ECM without using a factory
If the parameters exceed a trip point for a period of password.
time that is longer than the delay period, the ECM
logs an event code and the indicator switches ON.
Shutdown
The following parameters are monitored for event
codes: If the engine reaches the Shutdown condition,one of
the following events has occurred: low lubricating oil
• Lubricating Oil Pressure pressure, high coolant temperature or overspeed.
The event will be logged in the memory of the ECM.
• Coolant Temperature The engine will be shut down. A event code will be
transmitted over the Perkins Data link and the hard
• Overspeed wired Shutdown output will be energized. The
Shutdown condition will latch until the ECM is reset.
• Intake Manifold Temperature The event code for the shutdown can not be cleared
from the memory of the ECM without using a factory
• Intake Manifold Pressure password.

• Fuel Temperature Critical Protection Override

The temperature protection is disabled for a period of If the engine is in an application that is critical for
time when the engine is cranking in order to safety, the protection system can be overridden in
compensate for heat soak solutions. order to ensure the continuation of the power supply
during engine fault conditions.
The ECM has dedicated alarm outputs for each of the
three stages of protection. There are also dedicated Critical Protection Override will be set by a switch
alarm outputs for oil pressure, coolant temperature input from the OEM. For example, this may be a
and overspeed events which are energized at any switch to battery + in order to disable a critical
stage of protection. override. Critical Protection Override input can be
enabled in the electronic service tool by use of a
Warning Alarm factory password.

The Warning alarm informs the user that the engine

is approaching a critical condition.
SEBU8337-03 29
Operation Section
Monitoring System

When the Critical Protection Override feature is Note: It is not possible to reset the ECM by using the
active, the ECM will continue to run the engine in all Reset input until the engine has come to rest.
shutdown conditions with the exception of Overspeed
shutdown. If the shutdown is overridden a event code
is generated. The ECM will log the event code. The Altitude derate
ECM will energize the following: Warning, Action
Alert, Shutdown, oil pressure, coolant temperature At high altitudes or high ambient temperatures, the
and overspeed outputs as normal. The warranty of engine will be derated. The engine derate information
the engine will be invalidated if the engine is can be obtained from the Applications Department at
operated in the following conditions: active event Perkins Engines Company Limited Stafford.
code and Critical Protection Override mode.
Diagnostic
Standard Warning Outputs
If there is a fault with an engine protection sensor on
The ECM provides individual outputs in order to drive the engine, the engine activates a diagnostic code.
warning lamps or relays to indicate each of the The engine communicates the diagnostic code to the
following fault conditions: operator via the Diagnostic output. The diagnostic
code provides an indication to the operator of a fault
• Diagnostic Fault with the engine protection system. Running of the
engine for a prolonged period in this condition may
• Oil Pressure result in engine failure. The output is generally used
to drive lamps or relays.
• Coolant Temperature
The following sensors are monitored in order to
• Overspeed determine if the sensors are out of the normal range,
an open circuit or a short circuit:
• Action Alert
• Atmosphere Pressure
• Warning
• Lubricating Oil Pressure
• Shutdown
• Inlet Manifold Pressure
If the ECM detects a warning for the coolant
temperature , the output on the coolant temperature • Inlet Manifold Temperature
will be energized and the warning output will be
energized. If the ECM detects a warning for the low • Fuel Temperature
oil pressure, the output on the oil pressure will be
energized and the warning output will be energized. • Coolant Temperature

If the Action Alert alarms are enabled and the ECM • Engine Speed
detects a coolant temperature condition, the output
on the coolant Temperature will be energized and the • Desired Speed Input
output on the Action Alert will be energized.
The Diagnostic output differs from the Warning and
If the engine shuts down on low oil pressure the Shutdown outputs. The Warning and Shutdown
output on the low oil pressure will be energized and outputs refer to the operation of the engine. The
the output on the shutdown will be energized. If the Diagnostic output refers to the condition of the
engine shuts down on coolant temperature or the electronic system and software system.
engine shuts down on overspeed the dedicated
output and the shutdown output will be energized.

Shutdown Reset
The cause of an engine shutdown must be
investigated. Corrective action must be taken before
the system is reset in order to operate the engine.
After an engine shutdown, operate the reset input of
the ECM or power down the controller.
Powering down the electronic control module can be
achieved by the operation of the keyswitch into sleep
mode. The electronic control module can be powered
down by isolating the power supply to the electronic
control module.
30 SEBU8337-03
Operation Section
Sensors and Electrical Components

A diagnostic fault may develop on the lubricating oil

pressure or coolant temperature sensors. For
example, if a Shutdown protection sensor has a fault,
this will result in an engine shutdown, unless the
system is in critical protection override. If a diagnostic
fault occurs with one of the engine speed sensors
while the engine is running. The engine continues to
run by using the other timing sensor for reference.

i02772006

Sensors and Electrical

Components

Sensor Locations
Illustration 20 shows the typical locations of the
sensors on the engine. Specific engines may appear
different from the illustration due to differences in
applications.

Illustration 20 g01386180

(1) Engine coolant temperature sensor (4) Atmospheric pressure sensor (7) Fuel temperature sensor
(2) Intake manifold pressure sensor (5) Secondary position sensor (Camshaft) (8) Primary position sensor (Crankshaft)
(3) Intake manifold air temperature sensor (6) Engine oil pressure sensor (9) Electronic control module (ECM)
SEBU8337-03 31
Operation Section
Sensors and Electrical Components

Failure of Sensors Failure of the Coolant Temperature

Sensor
All Sensors
The ECM will detect a failure of the coolant
A failure of any of the sensors may be caused by one temperature sensor. The diagnostic lamp will warn
of the following malfunctions: the operator about the status of the coolant
temperature sensor. A failure of the coolant
• Sensor output is open. temperature sensor will cause a shutdown of the
engine. The faulty sensor should be replaced. Refer
• Sensor output is shorted to “- battery” or “+ to Disassembly and Assembly Manual, “Coolant
battery” . Temperature Sensor - Remove and Install”.

• Measured reading of the sensor is out of the Intake Manifold Pressure Sensor 2
specification.
The intake manifold pressure sensor measures boost
Programmable Monitoring System pressure in the intake manifold. A signal is sent to the
ECM. A failure of the inlet manifold pressure sensor
(PMS) will limit the power of the engine.
The Programmable Monitoring System determines
the level of action that is taken by the Engine Control
Intake Manifold Air Temperature
Module (ECM) in response to a condition that can Sensor 3
damage the engine. These conditions are identified
by the ECM from the signals that are produced from The Intake manifold air temperature sensor
the following sensors. measures the intake air temperature. A signal is sent
to the ECM. The intake manifold air temperature
sensor is also used by the ECM to determine
Engine Coolant Temperature initiation of the Cold Start Strategy.
Sensor 1
The coolant temperature sensor monitors engine
Atmospheric Pressure Sensor 4
coolant temperature. The output of the ECM can
indicate a high coolant temperature through a relay All the output signals from the pressure sensors are
or a lamp. The coolant temperature sensor is used by matched to the output signal of the atmospheric
the ECM to determine initiation of the Cold Start pressure sensor during calibration. The signal from
Condition. the atmospheric pressure sensor is used by the ECM
in order to determine the operating altitude of the
engine. If necessary, the ECM can derate the engine.

Secondary Speed/Timing Sensor 5

The signal from the secondary speed/timing sensor is
used by the ECM on engine start-up in order to
determine the stroke that the pistons are on. The
secondary speed/timing sensor may be used by the
ECM in order to operate the engine if the primary
speed/timing sensor is faulty.
In order to check the correct operation of the sensor,
refer to Troubleshooting, “Engine speed/Timing
sensor-Test”.

Engine Oil Pressure Sensor 6

The engine oil pressure sensor is an absolute
pressure sensor that measures the engine oil
pressure in the main oil gallery. The engine oil
pressure sensor detects engine oil pressure for
diagnostic purposes. The engine oil pressure sensor
sends a signal to the ECM .
32 SEBU8337-03
Operation Section
Sensors and Electrical Components

Low Oil Pressure Warning Intermittent failure of the sensors will cause erratic
engine control.
The setpoint for the low pressure warning is
dependent upon the engine speed. The fault will be Electronic Control Module 9
active and logged only if the engine has been running
for more than 8 seconds. The ECM controls the engine operating parameters
through the software within the ECM and the inputs
Low Oil Pressure from the various sensors. The software within the
ECM can be changed by installing a new flash file.
The very low oil pressure setpoint is dependent upon The flash file defines the following characteristics of
the engine speed. If very low oil pressure is detected, the engine:Engine power, Torque curves, Engine
the ECM will stop the engine immediately unless speed (rpm), Engine Noise, Smoke and Emissions.
Critical Events Override is active.

Failure of the Engine Oil Pressure Sensor

The ECM will detect failure of the engine oil pressure
sensor. The diagnostic lamp warns the user about
the status of the engine oil pressure sensor. The
engine oil pressure related strategies will be disabled
in the event of a failure of the engine oil pressure
sensor. A failure of the engine oil pressure sensor will
cause a shutdown of the engine. The faulty sensor
should be replaced. Refer to Disassembly and
assembly Manual, “Engine Oil Pressure Sensor -
Remove and Install”.

Fuel Temperature Sensor 7

The fuel temperature sensor monitors the fuel
temperature. The signal from the sensor allows the
ECM to compensate for changes in the fuel
temperature by adjusting the fuel rate for constant
power.

Primary Speed/Timing Sensor 8

If the ECM does not receive a signal from the primary
speed/timing sensor , the “DIAGNOSTIC” lamp will
indicate a diagnostic fault code which will be logged
in the ECM memory.
If the ECM does not receive a signal from the primary
speed/timing sensor (9), the ECM will read the signal
from the secondary speed/timing sensor (2). The
ECM continually checks in order to determine if there
is a signal from both sensors. If either sensor fails,
the faulty sensor should be replaced. Refer to
Disassembly and Assembly Manual, “Crankshaft
Position Sensor - Remove and Install” or refer to
Disassembly and Assembly Manual, “Camshaft
Position Sensor - Remove and Install”.
SEBU8337-03 33
Operation Section
Engine Diagnostics

Engine Diagnostics i02651197

i02784187
Engine Operation with Active
Diagnostic Codes
Self-Diagnostics
If a diagnostic lamp illuminates during normal engine
The electronic control module has some self- operation, the system has identified a situation that is
diagnostic ability. When an electronic problem with not within the specification. Use the electronic service
an input or an output is detected, a diagnostic code is tool to check the active diagnostic codes.
generated. This indicates the specific problem with
the circuitry. The active diagnostic code should be investigated.
The cause of the problem should be corrected as
A diagnostic code which represents a problem that soon as possible. If the cause of the active diagnostic
currently exists is called an active code. code is repaired and there is only one active
diagnostic code, the diagnostic lamp will turn off.
A diagnostic code that is stored in memory is called a
logged code. Always service active codes prior to Operation of the engine and performance of the
servicing logged codes. Logged codes may indicate engine can be limited as a result of the active
intermittent problems. diagnostic code that is generated. Acceleration rates
may be significantly slower and power outputs may
Logged codes may not indicate that a repair is be automatically reduced. Refer to Troubleshooting ,
needed. The problems may have been repaired since “Troubleshooting with a Diagnostic Code” for more
the logging of the code. Logged codes may be information on the relationship between each active
helpful to troubleshoot intermittent problems. diagnostic code and the possible effect on engine
performance.
i02572812
i02784585
Diagnostic Lamp
Engine Operation with
Intermittent Diagnostic Codes
The “DIAGNOSTIC” lamp is used to indicate the
existence of an active fault.
A fault diagnostic code will remain active until the If a diagnostic lamp illuminates during normal engine
problem is repaired. operation and the diagnostic lamp shuts OFF, an
intermittent fault may have occurred. If a fault has
i02784192
occurred, the fault will be logged into the memory of
the Electronic Control Module (ECM).
Fault Logging In most cases, it is not necessary to stop the engine
because of an intermittent code. However, the
operator should retrieve the logged fault codes and
The system provides the capability of Fault Logging. the operator should reference the appropriate
When the Electronic Control Module (ECM) information in order to identify the nature of the fault.
generates an active diagnostic code, the code will be The operator should log any observation that could
logged in the memory of the ECM. The Perkins have caused the lamp to light.
electronic service tool can retrieve codes that have
been logged. The codes that have been logged can • Low power
be cleared with the Perkins electronic service tool.
The codes that have been logged in the memory of • Limits of the engine speed
the ECM will be automatically cleared from the
memory after 100 hours. • Excessive smoke, etc
This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting guide for this
engine.
34 SEBU8337-03
Operation Section
Engine Starting

Engine Starting i02583442

i02773196
Starting the Engine
Before Starting Engine Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will
control the engine speed during start-up.
Before the engine is started, perform the required
daily maintenance and any other periodic
maintenance that is due. Refer to the Operation and New engines
Maintenance Manual, “Maintenance Interval
Schedule” for more information. Prime the turbocharger. This can be achieved by
cranking the engine briefly with no fuel.
• Open the fuel supply valve (if equipped).
If necessary, stop a new engine if an overspeed
condition occurs. If necessary, press the Emergency
NOTICE Stop button.
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing Starting the Engine
failure or other damage.
1. Move the ignition switch to the ON position. If a
If the engine has not been started for several weeks, system fault is indicated, investigate the cause. If
fuel may have drained from the fuel system. Air may necessary, use the Perkins electronic service tool.
have entered the filter housing. Also, when fuel filters
2. Push the start button or turn the keyswitch to the
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel START position in order to crank the engine.
system. Refer to the Operation and Maintenance 3. If the engine fails to start within 30 seconds,
Manual, “Fuel System - Prime” for more information
on priming the fuel system. release the start button or the ignition switch. Wait
for 30 seconds in order to allow the starting motor
to cool before attempting to start the engine again.
Note: A system fault may be indicated after the
Engine exhaust contains products of combustion engine is started. If this occurs the ECM has detected
which may be harmful to your health. Always a problem with the system. If necessary, use the
start and operate the engine in a well ventilated Perkins Service Tool to investigate the problem.
area and, if in an enclosed area, vent the exhaust
to the outside. Note: Oil pressure should rise within 15 seconds
after the engine starts. The engine electronic controls
• Do not start the engine or move any of the controls monitor the engine oil pressure. The electronic
if there is a “DO NOT OPERATE” warning tag or controls will stop the engine if the oil pressure is
similar warning tag attached to the start switch or below normal.
to the controls.

• Reset all of the shutoffs or alarm components (if

equipped).
• Ensure that any equipment that is driven by the
engine has been disengaged from the engine.
Minimize electrical loads or remove any electrical
loads.

• Ensure that the coolant level is correct.

• Ensure that the engine oil level is correct.
SEBU8337-03 35
Operation Section
Cold Weather Starting

4. When possible, allow the engine to run at no load Note: Oil pressure should rise within 15 seconds
for approximately three minutes. Run the engine at after the engine starts. The electronic engine controls
no load until the water temperature gauge has monitor the oil pressure. The electronic controls will
started to rise. Check all gauges during the warm- stop the engine if the oil pressure is below normal.
up period.
4. Operate the engine at no load until all the coolant
temperature starts to rise. Check the gauges
i02815193
during the warm-up period.
Cold Weather Starting Note: The oil pressures and fuel pressures should be
in the normal range on the instrument panel. Do not
apply a load to the engine until the oil pressure gauge
indicates at least normal pressure. Inspect the engine
for leaks and/or unusual noises.
Do not use aerosol types of starting aids such as Note: After the ECM has completed the cold mode,
ether. Such use could result in an explosion and cold mode cannot be enabled again until the ECM is
personal injury.
switched OFF.
The engine will start at a temperature of −10 °C
Note: Do not attempt to restart the engine until the
(14 °F). The ability to start at temperatures below
10 °C (50 °F) will improve by the use of a cylinder engine has completely stopped.
block coolant heater or a device which heats the
crankcase oil. This will help to reduce white smoke i02428473
and misfires when the engine is started in cold
weather. Starting with Jump Start
If the engine has not been run for several weeks, fuel Cables
may have drained. Air may have moved into the filter
housing. Also, when fuel filters have been changed,
some air will be left in the filter housing. Refer to
Operation and Maintenance Manual, “Fuel System - Do not use jump start cables in order to start the
Prime” in order to remove air from the fuel system. engine. Charge the batteries or replace the batteries.
Refer to Operation and Maintenance Manual,
Use the procedure that follows for cold weather “Battery - Replace”.
starting.
i01646248
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
After Starting Engine
If the engine fails to start within 30 seconds, release
the starter switch or button and wait thirty seconds to Note: In temperatures from 0 to 60°C (32 to 140°F),
allow the starting motor to cool before attempting to the warm-up time is approximately three minutes. In
start the engine again. temperatures below 0°C (32°F), additional warm-up
time may be required.
1. If equipped, press the start button. If equipped, Note: Ensure that the self test for the monitoring
turn the keyswitch to the START position in order system (if equipped) is completed before operating
to engage the electric starting motor and crank the the engine under load.
engine.
When the engine idles during warm-up, observe the
2. Repeat step 1 three times if the engine fails to following conditions:
start.
• Check for any fluid or for any air leaks at idle rpm
3. If the engine fails to start, investigate the problem. and at one-half full rpm (no load on the engine)
Use the Perkins electronic service tool. A system before operating the engine under load. This is not
fault may be indicated after the engine is started. If possible in some applications.
this occurs the ECM has detected a problem with
the system. Investigate the cause of the problem. • Operate the engine at low idle until all systems
Use the Perkins electronic service tool. achieve operating temperatures. Check all gauges
during the warm-up period.
36 SEBU8337-03
Operation Section
After Starting Engine

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.
SEBU8337-03 37
Operation Section
Engine Operation

Engine Operation • Ensure that the driven equipment is in good

working order.
i02578030 • Cold engines consume excess fuel. Keep cooling
system components clean and keep cooling
Engine Operation system components in good repair. Never operate
the engine without water temperature regulators.
All of these items will help maintain operating
Correct operation and maintenance are key factors in temperatures.
obtaining the maximum life and economy of the
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized.
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.

i02583385

Fuel Conservation Practices

The efficiency of the engine can affect the fuel

economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
in order to attain optimum performance for the life of
the engine.
• Avoid spilling fuel.
Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
• Be aware of the properties of the different fuels.
Use only the recommended fuels.
• Avoid unnecessary operation at no load.
Shut off the engine instead of operating the engine at
no load for long periods of time.

• Observe the service indicator for the air cleaner

frequently, if equipped. Keep the air cleaner
elements clean.

• Maintain a good electrical system.

One bad 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.
38 SEBU8337-03
Operation Section
Engine Stopping

Engine Stopping Ensure that any components for the external system
that support the engine operation are secured after
the engine is stopped.
i02572824
i02583411
Manual Stop Procedure
After Stopping Engine
Stopping the Engine
Note: Before you check the engine oil, do not
operate the engine for at least 10 minutes in order to
NOTICE allow the engine oil to return to the oil pan.
Stopping the engine immediately after it has been
working under load, can result in overheating and ac- • Check the crankcase oil level. Maintain the oil
celerated wear of the engine components. level between the “LOW” mark and the “HIGH”
Avoid accelerating the engine prior to shutting it mark on the oil level gauge.
down.
Note: Only use oil that is recommended in this
Avoiding hot engine shutdowns will maximize turbo- Operation and Maintenance Manual, “Fluid
charger shaft and bearing life. Recommendations”. Failure to use the recommended
oil may result in engine damage.

Note: Individual applications will have different • If necessary, perform minor adjustments. Repair
control systems. Ensure that the shutoff procedures any leaks and tighten any loose bolts.
are understood. Use the following general guidelines
in order to stop the engine. • Note the service hour meter reading. Perform the
maintenance that is in the Operation and
1. Remove the load from the engine. Allow the Maintenance Manual, “Maintenance Interval
engine to run under no load conditions for five Schedule”.
minutes in order to cool the engine.
• Fill the fuel tank in order to help prevent
2. Stop the engine after the cool down period accumulation of moisture in the fuel. Do not overfill
according to the shutoff system on the engine and the fuel tank.
turn the ignition keyswitch to the OFF position. If
• Allow the engine to cool. Check the coolant level.
necessary, refer to the instructions that are Maintain the cooling system at 13 mm (0.5 inch)
provided by the OEM. from the bottom of the pipe for filling.

Emergency Stopping Note: Only use coolant that is recommended in this

Operation and Maintenance Manual, “Fluid
Recommendations”. Failure to use the recommended
NOTICE oil may result in engine damage.
Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices • If freezing temperatures are expected, check the
or controls for normal stopping procedure. coolant for proper antifreeze protection. The
The OEM may have equipped the application with an cooling system must be protected against freezing
emergency stop button. For more information about to the lowest expected outside temperature. Add
the emergency stop button, refer to the OEM the proper coolant/water mixture, if necessary.
information.
• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.
SEBU8337-03 39
Operation Section
Cold Weather Operation

Cold Weather Operation

Personal injury or property damage can result
i02581613
from alcohol or starting fluids.
Cold Weather Operation Alcohol or starting fluids are highly flammable
and toxic and if improperly stored could result in
injury or property damage.
Perkins Diesel Engines can operate effectively in
cold weather. During cold weather, the starting and
the operation of the diesel engine is dependent on
the following items:
Do not use aerosol types of starting aids such as
• The type of fuel that is used ether. Such use could result in an explosion and
personal injury.
• The viscosity of the engine oil

• Optional Cold starting aid

Viscosity of the Engine Lubrication
• Battery condition Oil
The operation and maintenance of an engine in Correct engine oil viscosity is essential. Oil viscosity
freezing temperatures is complex . This is because of affects the amount of torque that is needed to crank
the following conditions: the engine. Refer to Operation and Maintenance
Manual, “Fluid Recommendations” for the
• Weather conditions recommended viscosity of oil.
• Engine applications
Recommendations for the Coolant
Recommendations from your Perkins distributor are
based on past proven practices. The information that Provide cooling system protection for the lowest
is contained in this section provides guidelines for expected outside temperature. Refer to this
cold weather operation. Operation and Maintenance Manual, “Fluid
Recommendations” for the recommended coolant
mixture.
Hints for Cold Weather Operation
In cold weather, check the coolant often for the
• If the engine will start, operate the engine until a correct glycol concentration in order to ensure
minimum operating temperature of 81 °C adequate freeze protection.
(177.8 °F) is achieved. Achieving operating
temperature will help prevent the intake valves Engine Block Heaters
and exhaust valves from sticking.
Engine block heaters (if equipped) heat the engine
• The cooling system and the lubrication system for jacket water that surrounds the combustion
the engine do not lose heat immediately upon chambers. This provides the following functions:
shutdown. This means that an engine can be shut
down for a period of time and the engine can still • Startability is improved.
have the ability to start readily.
An electric block heater can be activated once the
engine is stopped. An effective block heater is
• Install the correct specification of engine lubricant
typically a 1250/1500 W unit. Consult your Perkins
before the beginning of cold weather. distributor for more information.
• Check all rubber parts (hoses, fan drive belts, etc)
i02576035
weekly.
• Check all electrical wiring and connections for any Fuel and the Effect from Cold
fraying or damaged insulation.
Weather
• Keep all batteries fully charged and warm.
• Check the air cleaners and the air intake daily. Note: Only use grades of fuel that are recommended
by Perkins. Refer to this Operation and Maintenance
Manual, “Fluid Recommendations”.
40 SEBU8337-03
Operation Section
Fuel Related Components in Cold Weather

The following fuels can be used in this series of The pour point is the temperature when diesel fuel
engine. will thicken. The diesel fuel becomes more resistant
to flow through fuel lines, fuel filters,and fuel pumps.
• Group 1
Be aware of these facts when diesel fuel is
• Group 2 purchased. Consider the average ambient air
temperature for the engine's application. Engines that
• Group 3 are fueled in one climate may not operate well if the
engines are moved to another climate. Problems can
• Special Fuels result due to changes in temperature.

Perkins prefer only Group 1 and Group 2 fuels for Before troubleshooting for low power or for poor
use in this series of engines. performance in the winter, check the fuel for waxing.

Group 1 fuels are the preferred Group of Fuels for Low temperature fuels may be available for engine
general use by Perkins. Group 1 fuels maximize operation at temperatures below 0 °C (32 °F). These
engine life and engine performance. Group 1 fuels fuels limit the formation of wax in the fuel at low
are usually less available than Group 2 fuels. temperatures.
Frequently, Group 1 fuels are not available in colder
climates during the winter. For more information on cold weather operation, refer
to the Operation and Maintenance Manual, “Cold
Note: Group 2 fuels must have a maximum wear Weather Operation and Fuel Related Components in
scar of 650 micrometers (HFRR to ISO 12156-1). Cold Weather”.

Group 2 fuels are considered acceptable for issues of i02583420

warranty. This group of fuels may reduce the life of
the engine, the engine's maximum power, and the Fuel Related Components in
engine's fuel efficiency.
Cold Weather
When Group 2 diesel fuels are used the following
components provide a means of minimizing problems
in cold weather:
Fuel Tanks
• Glow plugs (if equipped)
Condensation can form in partially filled fuel tanks.
• Engine coolant heaters, which may be an OEM Top off the fuel tanks after you operate the engine.
option
Fuel tanks should contain some provision for draining
• Fuel heaters, which may be an OEM option water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
• Fuel line insulation, which may be an OEM option and sediment to settle below the end of the fuel
supply pipe.
There are three major differences between Group 1
fuels and Group 2 fuels. Group 1 fuels have the Some fuel tanks use supply lines that take fuel
following different characteristics to Group 2 fuels. directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
• A lower cloud point the fuel system filter is important.

• A lower pour point Drain the water and sediment from any fuel storage
tank at the following intervals: weekly, oil changes
• A lower energy per unit volume of fuel and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
Note: Group 3 fuels reduce the life of the engine. The fuel storage tank and into the engine fuel tank.
use of Group 3 fuels is not covered by the Perkins
warranty. Fuel Filters
Group 3 fuels include Low Temperature Fuels and A primary fuel filter is installed between the fuel tank
Aviation Kerosene Fuels. and the engine fuel inlet. After you change the fuel
Special fuels include Biofuel. filter, always prime the fuel system in order to remove
air bubbles from the fuel system. Refer to the
The cloud point is a temperature that allows wax Operation and Maintenance Manual in the
crystals to form in the fuel. These crystals can cause Maintenance Section for more information on priming
the fuel filters to plug. the fuel system.
SEBU8337-03 41
Operation Section
Fuel Related Components in Cold Weather

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.
42 SEBU8337-03
Maintenance Section
Refill Capacities

Maintenance Section (Table 4, contd)

(1) The External System includes a radiator or an expansion tank
with the following components: heat exchanger and piping. Re-
fer to the OEM specifications. Enter the value for the capacity
Refill Capacities of the External System in this row.

i09711118
i02793514

Refill Capacities Fluid Recommendations

(Fuel Specification)

Lubrication System • Glossary

The refill capacities for the engine crankcase reflect • ISO International Standards Organization
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will • ASTM American Society for Testing and Materials
require additional oil. Refer to the OEM specifications
for the capacity of the auxiliary oil filter. Refer to the • HFRR High Frequency Reciprocating Rig for
Operation and Maintenance Manual, “Maintenance Lubricity testing of diesel fuels
Section” for more information on Lubricant
Specifications. • FAME Fatty Acid Methyl Esters
Table 3
• CFR Co-ordinating Fuel Research
Engine
Refill Capacities • LSD Low Sulfur Diesel
Compartment or System Maximum
• ULSD Ultra Low Sulfur Diesel
Crankcase Oil Sump(1) 40 L (8.8 Imp gal)
• RME Rape Methyl Ester
(1) These values are the approximate capacities for the crankcase
oil sump (aluminum) which includes the standard factory in- • SME Soy Methyl Ester
stalled oil filters. Engines with auxiliary oil filters will require ad-
ditional oil. Refer to the OEM specifications for the capacity of
the auxiliary oil filter. • EPA Environmental Protection Agency of the
United States
Cooling System General Information
Refer to the OEM specifications for the External
System capacity. This capacity information will be NOTICE
needed in order to determine the amount of coolant Every attempt is made to provide accurate, up-to-
that is required for the Total Cooling System. date information. By use of this document you agree
Table 4 that Perkins Engines Company Limited is not respon-
sible for errors or omissions.
Engine
Refill Capacities

Compartment or System Liters NOTICE

These recommendations are subject to change with-
Engine Only
15 L out notice. Contact your local Perkins distributor for
(3.3 Imp gal) the latest, up-to-date recommendations.
25.5 L
External System Per OEM(1) Refer to Perkins Diesel Engines Fluids
(5.6 Imp gal)
Recommendations, M0113102 for additional
information that relates to fuel.

(continued) Diesel Fuel Requirements

Satisfactory engine performance depends on the use
of a good quality fuel. The use of a good quality fuel
will give the following results: long engine life and
acceptable exhaust emissions levels. The fuel must
meet the minimum requirements that are stated in
table 5 .
SEBU8337-03 43
Maintenance Section
Fuel Specification

NOTICE
The footnotes are a key part of the Perkins Specifica-
tion for Distillate Diesel Fuel Table. Read ALL of the
footnotes.

Table 5
Perkins Specification for Distillate Diesel Fuel(1)

Property UNITS Requirements “ASTM”Test “ISO”Test

Aromatics %Volume 35% maximum D1319 “ISO”3837

Ash %Weight 0.01% maximum D482 “ISO”6245

Carbon Residue on 10% %Weight 0.35% maximum D524 “ISO”4262

Bottoms
Cetane Number (2) - 40 minimum D613/D6890 “ISO”5165

Cloud Point °C The cloud point must not ex- D2500 “ISO”3015
ceed the lowest expected
ambient temperature.

Copper Strip Corrosion - No. 3 maximum D130 “ISO”2160

3
Density at 15 °C (59 °F) Kg / M 801 minimum and 876 No equivalent test “ISO 3675”“ISO 12185”
(3) maximum

Distillation °C 10% at 282 °C (539.6 °F) D86 “ISO”3405

maximum
90% at 360 °C (680 °F)
maximum
Flash Point °C legal limit D93 “ISO”2719

Thermal Stability - Minimum of 80% reflec- D6468 No equivalent test

tance after aging for 180 mi-
nutes at 150 °C (302 °F)

Pour Point °C 6 °C (42.8 °F) minimum be- D97 “ISO”3016

low ambient temperature

Sulfur (1) (4) %mass 1% maximum D5453/D26222 “ISO 20846”“ISO 20884”

(5) 2
Kinematic Viscosity “MM” “/S (cSt)” The viscosity of the fuel that D445 “ISO”3405
is delivered to the fuel injec-
tion pump. “1.4 minimum/
4.5 maximum”
Water and sediment % weight 0.1% maximum D1796 “ISO”3734

Water % weight 0.1% maximum D1744 No equivalent test

Sediment % weight 0.05% maximum D473 “ISO”3735

Gums and Resins (6) mg/100mL 10 mg per 100 mL D381 “ISO”6246

maximum
Lubricity correctedwear mm 0.52 maximum D6079 “ISO”12156-1
scar diameter at 60 °C
(140 °F). (7)
(1) This specification includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to
“ASTM D5453”, “ASTM D2622”, or “ISO 20846, ISO 20884” test methods. This specification includes the requirements for Low Sulfur Diesel
(LSD). LSD fuel will have ≤500 ppm (0.05%) sulfur. Refer to following:“ASTM 5453, ASTM D2622”, “ISO 20846” and “ISO 20884 test
methods”.
(2) A fuel with a higher cetane number is recommended to operate at a higher altitude or in cold-weather.
(3) “Via standards tables, the equivalent API gravity for the minimum density of 801 kg / m3 (kilograms per cubic meter) is 45 and for the maxi-
mum density of 876 kg / m3 is 30”.

(continued)
44 SEBU8337-03
Maintenance Section
Fuel Specification

(Table 5, contd)
(4) Regional regulations, national regulations, or international regulations can require a fuel with a specific sulfur limit. Consult all applicable reg-
ulations before selecting a fuel for a given engine application. Perkins fuel systems and engine components can operate on high sulfur fuels.
Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal components. Fuel sulfur lev-
els above 0.5% may significantly shorten the oil change interval. For additional information, refer to this manual, “Fluid recommendations
(General lubricant Information)”.
(5) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscos-
ity requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the “ASTM D445” test method or
the “ISO 3104” test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain 1.4 cSt or greater viscosity at
the fuel injection pump. Fuels with a high viscosity might require fuel heaters to lower the viscosity to 4.5 cSt at the fuel injection pump.
(6) Follow the test conditions and procedures for gasoline (motor).
(7) The lubricity of a fuel is a concern with low sulfur, and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or
ASTM D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your
fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause prob-
lems in the fuel system.

The viscosity of the fuel is significant because fuel

NOTICE serves as a lubricant for the fuel system components.
Operating with fuels that do not meet the Perkins rec-
ommendations can cause the following effects: Start- Fuel must have sufficient viscosity to lubricate the
ing difficulty, poor combustion, deposits in the fuel fuel system in both extremely cold temperatures and
injectors, reduced service life of the fuel system, de- extremely hot temperatures. If the kinematic viscosity
posits in the combustion chamber and reduced serv- of the fuel is lower than 1.4 cSt at the fuel injection
ice life of the engine. pump damage to the fuel injection pump can occur.
This damage can be excessive scuffing and seizure.
Low viscosity may lead to difficult hot restarting,
stalling, and loss of performance. High viscosity may
Diesel Fuel Characteristics result in seizure of the pump.
Perkins Recommendation Perkins recommends kinematic viscosities of 1.4 and
4.5 mm2/sec that is delivered to the fuel injection
Cetane Number pump.

Fuel that has a high cetane number will give a shorter Density
ignition delay. This will produce a better ignition
quality. Cetane numbers are derived for fuels against Density is the mass of the fuel per unit volume at a
proportions of cetane and heptamethylnonane in the specific temperature. This parameter has a direct
standard CFR engine. Refer to “ISO 5165” for the influence on engine performance and a direct
test method. influence on emissions. This determines the heat
output from a given injected volume of fuel. This is
Cetane numbers more than 45 are normally expected quoted in the following kg/m at 15 °C (59 °F).
from current diesel fuel. However, a cetane number
of 40 may be experienced in some territories. The Perkins recommends a value of density of 841 kg/m
United States of America is one of the territories that to obtain the correct power output. Lighter fuels are
can have a low cetane value. A minimum cetane acceptable but these fuels will not produce the rated
value of 40 is required during average starting power.
conditions. A higher cetane value may be required for
operations at high altitudes or in cold-weather Sulfur
operations.
Fuel with a low cetane number can be the root cause The level of sulfur is governed by emissions
of problems during cold start. legislations. Regional regulation, national
regulations, or international regulations can require a
fuel with a specific sulfur limit. The sulfur content of
Viscosity the fuel and the fuel quality must comply with all
existing local regulations for emissions.
Viscosity is the property of a liquid of offering
resistance to shear or flow. Viscosity decreases with
increasing temperature. This decrease in viscosity
follows a logarithmic relationship for normal fossil
fuel. The common reference is to kinematic viscosity.
This is the quotient of the dynamic viscosity that is
divided by the density. The determination of
kinematic viscosity is normally by readings from
gravity flow viscometers at standard temperatures.
Refer to “ISO 3104” for the test method.
SEBU8337-03 45
Maintenance Section
Fuel Specification

By using the test methods “ASTM D5453, ASTM Distillation

D2622, or ISO 20846 ISO 20884”, the content of
sulfur in low sulfur diesel (LSD) fuel must be below This is an indication of the mixture of different
500 PPM 0.05%. By using the test methods “ASTM hydrocarbons in the fuel. A high ratio of lightweight
D5453, ASTM D2622, or ISO 20846 ISO 20884”, the hydrocarbons can affect the characteristics of
content of sulfur in ultra low sulfur (ULSD) fuel must combustion.
be below 15 PPM 0.0015%. The use of LSD fuel and
the use of ULSD fuel are acceptable as long as the Classification of the Fuels
fuels meet the minimum requirements that are stated
in table 5 . The lubricity of these fuels must not Diesel engines have the ability to burn a wide variety
exceed wear scar diameter of 0.52 mm of fuels. These fuels are divided into four general
(0.0205 inch). The fuel lubricity test must be groups: Ref to table 6
performed on a HFRR, operated at 60 °C (140 °F).
Refer to “ISO 12156-1”. Table 6
Fuel Groups Classification
In some parts of the world and for some applications,
high sulfur fuels above 0.5% by mass might only be Group 1 Preferred fuels Full life of the
available. Fuel with very high sulfur content can Product
cause engine wear. High sulfur fuel will have a
negative impact on emissions of particulates. High Group 2 Permissible fuels with These fuelsMAY
an appropriate fuel cause reduced en-
sulfur fuel can be used as long as the local emissions
additive gine life and
legislation will allow the use. High sulfur fuel can be
performance
used in countries that do not regulate emissions.
Group 3 Permissible fuels with These fuelsWILL
When only high sulfur fuels are available, it will be an appropriate fuel cause reduced en-
necessary that high alkaline lubricating oil is used in additive gine life and
the engine or that the lubricating oil change interval is performance
reduced. Refer to this Operation and Maintenance
Manual, “Fluid Recommendations (General Group 4 Biodiesel
Lubrication Information)” for information on sulfur in
fuel.
Group 1 Specifications (Preferred Fuels)
Lubricity
This group of fuel specifications is considered
This is the capability of the fuel to prevent pump acceptable:
wear. The fluid's lubricity describes the ability of the
fluid to reduce the friction between surfaces that are • EN590 DERV Grade A, B, C, E, F, Class, 0, 1, 2, 3
under load. This ability reduces the damage that is and 4
caused by friction. Fuel injection systems rely on the
lubricating properties of the fuel. Until fuel sulfur limits • “BS2869 Class A2” Off-Highway Gas Oil Red
were mandated, the fuel's lubricity was believed to be Diesel
a function of fuel viscosity.
• “ASTM D975”, Class 1D and Class 2D
The lubricity has particular significance to the current
low viscosity fuel, low sulfur fuel, and low aromatic • “JIS K2204 Grades 1,2,3 and Special Grade 3”
fossil fuel. These fuels are made to meet stringent This grade of fuel must meet the minimum lubricity
exhaust emissions. A test method for measuring the requirements that are stated in table 5 .
lubricity of diesel fuels has been developed and the
test is based on the HFRR method that is operated at Note: The use of LSD fuel and the use of ULSD fuel
60 °C (140 °F). Refer to “ISO 12156 part 1 and CEC is acceptable as long as the fuels meet the minimum
document F06-A-96” for the test method. requirements that are stated in table 5 . The lubricity
of these fuels must not exceed wear scar diameter of
Lubricity wear scar diameter of 0.52 mm 0.52 mm (0.0205 inch). The lubricity test must be
(0.0205 inch) MUST NOT be exceeded. The fuel
performed on a HFRR, operated at 60 °C (140 °F).
lubricity test must be performed on a HFRR,
operated at 60 °C (140 °F). Refer to “ISO 12156-1”. Refer to “ISO 12156-1”. By using the test methods
“ASTM D5453, ASTM D2622, or ISO 20846 ISO
Fuel additives can enhance the lubricity of a fuel. 20884”, the content of sulfur in LSD fuel must be
Contact your fuel supplier for those circumstances below 500 PPM 0.05%. By using the test methods
when fuel additives are required. Your fuel supplier “ASTM D5453, ASTM D2622, or ISO 20846 ISO
can make recommendations for additives to use and 20884”, the content of sulfur in ULSD fuel must be
for the proper level of treatment. For more below 15 PPM 0.0015%.
information, refer to “Fuel Additive”.
46 SEBU8337-03
Maintenance Section
Fuel Specification

Group 2 Specifications (Permissible Group 4 Biodiesel

Fuels)
Biodiesel is a fuel that can be defined as mono-alkyl
This group of fuel specifications is considered esters of fatty acids. Biodiesel is a fuel that can be
acceptable, but only with an appropriate fuel additive, made from various feedstock. The most commonly
but these fuels MAY reduce the engine life and available biodiesel in Europe is Rape Methyl Ester
performance. (REM). This biodiesel is derived from rapeseed oil.
Soy Methyl Ester (SME) is the most common
• “MIL-DTL-83133E NATO F34 (JP-8)” biodiesel in the United States. This biodiesel is
derived from soybean oil. Soybean oil or rapeseed oil
• “MIL-DTL-83133E NATO F35” are the primary feedstocks. These fuels are together
known as Fatty Acid Methyl Esters (FAME).
• “MIL-DTL-5624U NATO F44 (JP-5)”
Raw pressed vegetable oils are NOT acceptable for
• “MIL-DTL-38219D (USAF) F44 JP-7” use as a fuel in any concentration in compression
engines. Without esterification, these oils gel in the
• “NATO F63” crankcase and the fuel tank. These fuels may not be
compatible with many of the elastomers that are used
• “NATO XF63” in engines that are manufactured today. In original
forms, these oils are not suitable for use as a fuel in
• “ASTM D1655 JET A” compression engines. Alternate base stocks for
biodiesel may include animal tallow, waste cooking
• “ASTM D1655 JET A1” oils, or various other feedstocks. To use any of the
products that are listed as fuel, the oil must be
Note: These fuels are only acceptable as long as esterified.
these fuels are used with an appropriate fuel additive.
These fuels must meet the requirements that are Note: Engines that are manufactured by Perkins are
stated in table 5 . Fuel samples should be analyzed certified by use of the prescribed Environmental
for the compliance. These fuels MUST NOT exceed Protection Agency (EPA) and European Certification
lubricity wear scar diameter of 0.52 mm fuels. Perkins does not certify engines on any other
(0.0205 inch). The fuel lubricity test must be fuel. The user of the engine has the responsibility of
performed on a HFRR, operated at 60 °C (140 °F). using the correct fuel that is recommended by the
Refer to “ISO 12156-1”. Fuels must have minimum manufacturer and allowed by the EPA and other
viscosity of 1.4 centistokes that is delivered to the appropriate regulatory agencies.
fuel injection pump. Fuel cooling may be required to
Recommendation for the use of biodiesel
maintain minimum viscosity of 1.4 centistokes that is
delivered to the fuel injection pump. The neat biodiesel must conform to “EN14214” or
“ASTM D6751” regulations. A maximum of 30%
Group 3 Specifications (Permissible mixture of biodiesel can be used in mineral diesel
Fuels) fuel. The mineral diesel fuel must conform to
“EN590”, “ASTM D975” or “BS2869 Grade A2”
regulations.
This group of fuel specification must be used only
with the appropriate fuel additive. This fuel WILL Note: When biodiesel, or any blend of biodiesel is
reduce engine life and performance. used, the user has the responsibility for obtaining the
proper local exemptions, regional exemptions, and/or
“JIS 2203#1 and #2 Toyu” national exemptions that are required for the use of
Note: These fuels are only acceptable as long as biodiesel in any Perkins engine that is regulated by
these fuels are used with an appropriate fuel additive. emissions standards. Biodiesel that meets EN 14214
These fuels must meet the requirements that are is acceptable. The biodiesel must be blended with an
stated in table 5 . Fuel samples should be analyzed acceptable distillate diesel fuel at the maximum
for the compliance. These fuels MUST NOT exceed stated percentages. However, the following
lubricity wear scar diameter of 0.52 mm operational recommendations must be followed:
(0.0205 inch). The fuel lubricity test must be • The oil change interval can be affected by the use
performed on a HFRR, operated at 60 °C (140 °F). of biodiesel. Use Services Oil Analysis to monitor
Refer to “ISO 12156-1”. Fuels must have minimum the condition of the engine oil. Use Services Oil
viscosity of 1.4 centistokes that is delivered to the Analysis also to determine the oil change interval
fuel injection pump. Fuel cooling may be required to that is optimum.
maintain minimum viscosity of 1.4 centistokes that is
delivered to the fuel injection pump. • Confirm that biodiesel is acceptable for use with
the manufacturer of the fuel filters.
SEBU8337-03 47
Maintenance Section
Fuel Specification

• In a comparison of distillate fuels to biodiesel, Fuel for Cold-Weather Operation

biodiesel provides less energy per gallon by 5% to
7%. Do NOT change the engine rating to The European standard “EN590” contains climate
compensate for the power loss. This will help dependant requirements and a range of options. The
avoid engine problems when the engine is options can be applied differently in each country.
converted back to 100 percent distillate diesel fuel. There are 5 classes that are given to arctic climates
and severe winter climates. 0, 1, 2, 3 and 4.
• The compatibility of the elastomers with biodiesel
Fuel that complies with “EN590” CLASS 4 can be
is being monitored. The condition of seals and
used at temperatures as low as −44 °C (−47.2 °F).
hoses should be monitored regularly. Refer to “EN590” for a detailed discretion of the
physical properties of the fuel.
• Biodiesel may pose low ambient temperature
problems for both storage and operation. At low The diesel fuel “ASTM D975 1-D” that is used in the
ambient temperatures, fuel may need to be stored United States of America may be used in very cold
in a heated building or a heated storage tank. The temperatures that are below −18 °C (−0.4 °F).
fuel system may require heated fuel lines, filters,
and tanks. Filters may plug and fuel in the tank In extreme cold ambient conditions, you may also
may solidify at low ambient temperatures if use fuels that are listed in the table 7 . These fuels
are intended to be used in temperatures that can be
precautions are not taken. Consult your biodiesel as low as −54 °C (−65.2 °F).
supplier for assistance in the blending and
Table 7
attainment of the proper cloud point for the fuel.
Light Distillate Fuels (1)
• Biodiesel has poor oxidation stability, which can
result in long term problems in the storage of Specification Grade
biodiesel. The poor oxidation stability may “MIL-DTL-5624U” JP-5
accelerate fuel oxidation in the fuel system. This is
especially true in engines with electronic fuel “MIL-DTL-83133E” JP-8
systems because these engines operate at higher “ASTM D1655” Jet-A-1
temperatures. Consult the fuel supplier for (1) The use of these fuels is acceptable with an appropriate fuel
oxidation stability additives. additive and the fuels must meet minimum requirements that
are stated in Table 5 . Fuel samples should be analyzed for the
• Biodiesel is a fuel that can be made from various compliance. Fuels MUST NOT exceed 0.52 mm lubricity wear
feedstock. The feedstock that is used can affect scar diameter that is tested on a HFFR . The test must be per-
the performance of the product. Two of the formed at 60 °C. Refer to “ISO 12156-1”. Fuels must have mini-
mum viscosity of 1.4 centistokes that is delivered to the fuel
characteristics of the fuel that are affected are cold injection pump. Fuel cooling may be required to maintain mini-
flow and oxidation stability. Contact your fuel mum viscosity of 1.4 centistokes that is delivered to the fuel in-
supplier for guidance. jection pump.

• Biodiesel or biodiesel blends are not

recommended for engines that will operate
occasionally. This is due to poor oxidation stability.
If the user is prepared to accept some risk, then Mixing alcohol or gasoline with diesel fuel can
limit biodiesel to a maximum of B5. Examples of produce an explosive mixture in the engine
applications that should limit the use of biodiesel crankcase or the fuel tank. Alcohol or gasoline
must not be used in order to dilute diesel fuel.
are the following: Standby Generator sets and Failure to follow this instruction may result in
certain emergency vehicles death or personal injury.
• Biodiesel is an excellent medium for microbial
contamination and growth. Microbial There are many other diesel fuel specifications that
contamination and growth can cause corrosion in are published by governments and by technological
the fuel system and premature plugging of the fuel societies. Usually, those specifications do not review
filter. The use of conventionalanti-microbial all the requirements that are addressed in table 5 . To
additives and the effectiveness of conventional ensure optimum engine performance, a complete
anti-microbial additives in biodiesel is not known. fuel analysis should be obtained before engine
Consult your supplier of fuel and additive for operation. The fuel analysis should include all of the
assistance. properties that are stated in the table 5 .

• Care must be taken to remove water from fuel

tanks. Water accelerates microbial contamination
and growth. When biodiesel is compared to
distillate fuels, water is naturally more likely to
exist in the biodiesel.
48 SEBU8337-03
Maintenance Section
Fluid Recommendations

Fuel Additive NOTICE

If the engine is to be stored in, or shipped to an area
Supplemental diesel fuel additives are not generally
recommended. This is due to potential damage to the with below freezing temperatures, the cooling system
must be either protected to the lowest outside tem-
fuel system or the engine. Your fuel supplier or the
perature or drained completely to prevent damage.
fuel manufacturer will add the appropriate
supplemental diesel fuel additives.
Perkins recognizes the fact that additives may be NOTICE
required in some special circumstances. Fuel Frequently check the specific gravity of the coolant
additives need to be used with caution. Contact your for proper freeze protection or for anti-boil protection.
fuel supplier for those circumstances when fuel
additives are required. Your fuel supplier can Clean the cooling system for the following reasons:
recommend the appropriate fuel additive and the
correct level of treatment. • Contamination of the cooling system

Note: For the best results, your fuel supplier should • Overheating of the engine
treat the fuel when additives are required. The
• Foaming of the coolant
treated fuel must meet the requirements that are
stated in table 5 .
NOTICE
Perkins Diesel Fuel System Cleaner Never operate an engine without water temperature
regulators in the cooling system. Water temperature
Perkins Fuel Cleaner (part number T400012) is the regulators help to maintain the engine coolant at the
only fuel cleaner that is recommended by Perkins. proper operating temperature. Cooling system prob-
lems can develop without water temperature
If biodiesel or biodiesel blends of fuel are to be used, regulators.
Perkins require the use of Perkins fuel cleaner. The
use of the fuel is to remove deposits within the fuel
system that is created with the use of biodiesel. For Many engine failures are related to the cooling
more information on the use of biodiesel and system. The following problems are related to cooling
biodiesel blends refer to “Group 4 Biodiesel”. system failures: Overheating, leakage of the water
pump and plugged radiators or heat exchangers.
Perkins fuel cleaner will remove deposits that can
form in the fuel system with the use of biodiesel and These failures can be avoided with correct cooling
biodiesel blends. These deposits can create a loss of system maintenance. Cooling system maintenance is
power and engine performance. as important as maintenance of the fuel system and
the lubrication system. Quality of the coolant is as
Once the fuel cleaner has been added to the fuel, the important as the quality of the fuel and the lubricating
deposits within the fuel system are removed after 30 oil.
hours of engine operation. For maximum results,
continue to use the fuel cleaner for up to 80 hours. Coolant is normally composed of three elements:
Perkins fuel cleaner can be used on an on-going Water, additives, and glycol.
basis with no adverse impact on engine or fuel
system durability. Refer to Perkins Diesel Engines Fluids
Recommendations, M0113102 for additional
Detailed instructions on the rate of which the fuel information that relates to coolant.
cleaner must be used are on the container.
Water
i09711151
Water is used in the cooling system to transfer heat.
Fluid Recommendations Note: The water must be used with an inhibitor to
protect the engine.
Distilled water or deionized water is
Cooling System Specifications 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 8
.
SEBU8337-03 49
Maintenance Section
Fluid Recommendations

Table 8
Acceptable Water • Cavitation of the water pump
Property Maximum Limit For optimum performance, Perkins recommends a
Chloride (Cl) 40 mg/L 50 percent by volume of glycol in the finished coolant
(also referred to as 1:1 mixture).
Sulfate (SO4) 100 mg/L
Note: Use a mixture that will provide protection
Total Hardness 170 mg/L against the lowest ambient temperature.
Total Solids 340 mg/L
Note: 100 percent pure glycol will freeze at a
Acidity pH of 5.5 to 9.0 temperature of −13 °C (8.6 °F).
Most conventional antifreezes use ethylene glycol.
For a water analysis, consult one of the following Propylene glycol may also be used. In a 1:1 mixture
sources: with water, ethylene and propylene glycol provide
similar protection against freezing and boiling. See
• Local water utility company Tables 9 and 10 .
Table 9
• Agricultural agent
Ethylene Glycol
• Independent laboratory
Concentration Freeze Protection
Additives 50 Percent −36 °C (−33 °F)

Additives help to protect the metal surfaces of the 60 Percent −51 °C (−60 °F)
cooling system. A lack of coolant additives or
insufficient amounts of additives enable the following
conditions to occur: NOTICE
Do not use propylene glycol in concentrations that
• Corrosion exceed 50 percent glycol because of the reduced
heat transfer capability of propylene glycol. Use ethyl-
• Formation of mineral deposits ene glycol in conditions that require additional protec-
tion against boiling or freezing.
• Rust
Table 10
• Scale
Propylene Glycol
• Foaming of the coolant
Concentration Freeze Protection
Many additives are depleted during engine operation.
These additives must be replaced periodically. 50 Percent −29 °C (−20 °F)

Additives must be added at the correct concentration. To check the concentration of glycol in the coolant,
Over concentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can measure the specific gravity of the coolant.
enable the following problems to occur:
Note: Some commercially available coolants are
• Formation of gel compounds based on alternative fluids, such as 1, 3-propanediol
(beta-propylene glycol, PDO), glycerin (glycerol), or
• Reduction of heat transfer mixtures of these alternatives with ethylene/
propylene glycols. At the time of publication of this
• Leakage of the water pump seal document no industry standard exists for coolants
based on these chemicals. Until such standard/
• Plugging of radiators, coolers, and small passages specifications are published and evaluated by
Perkins, use of PDO, glycerine, or other alternative
Glycol coolants is not recommended in Perkins diesel
engines.
Glycol in the coolant helps to provide protection
against the following conditions: Coolant Recommendations
• Boiling
• ELC Extended Life Coolant
• Freezing
• SCA Supplement Coolant Additive
50 SEBU8337-03
Maintenance Section
Fluid Recommendations

• ASTM American Society for Testing and Refer to Perkins Diesel Engines Fluids
Materials Recommendations, M0113102 for additional
information that relates to coolant.
ELC - extended life coolant. A coolant that relies on Table 11
organic inhibitors for corrosion and cavitation
protection. Also called OAT coolant (Organic Acid Coolant Service Life
Technology). Coolant Type Service Life (1)

SCA - supplemental coolant additive, concentrated 6,000 Service Hours or Three

Perkins ELC
inorganic inhibitor package. Years

Extender - concentrated organic inhibitor package. Commercial Heavy-Duty Anti-

freeze that meets “ASTM 3000 Service Hours or Two Years
Conventional Coolant - a coolant that relies on D6210”
inorganic inhibitors for corrosion and cavitation
Commercial Heavy-Duty Anti-
protection. freeze that meets “ASTM 3000 Service Hours or One Year
D4985”
Hybrid Coolant - a coolant in which the corrosion and
cavitation protection is based on a mixture of organic Commercial SCA and Water 3000 Service Hours or One Year
and inorganic inhibitors. (1) Use the interval that occurs first. The cooling system must also
be flushed out at this time.
The following two coolants are used in Perkins diesel
engines:
Perkins Extended Life Coolant (ELC)
Preferred – Perkins Extended Life Coolant (ELC)
Perkins provides Extended Life Coolant (ELC) for
Acceptable – A commercial heavy-duty antifreeze use in the following applications:
that meets “ASTM D6210” or “ASTM D4985” • Heavy-duty spark ignited gas engines
specifications.
• Heavy-duty diesel engines
NOTICE • Automotive applications
Do not use a commercial coolant/antifreeze that only
meets the ASTM D3306 specification. This type of The anti-corrosion package for ELC is different from
coolant/antifreeze is made for light automotive the anti-corrosion package for other coolants. ELC is
applications. an ethylene glycol base coolant. However, ELC
contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrite. Perkins ELC has
NOTICE been formulated with the correct amount of these
A commercial heavy-duty antifreeze that meets additives to provide superior corrosion protection for
“ASTM D4985” specification requires a treatment all metals in engine cooling systems.
with an SCA at the initial fill. Read the label or the in-
structions that are provided by the manufacturer of ELC is available in a premixed cooling solution with
the product. distilled water. ELC is a 50 percent by volume of
glycol mixture. The Premixed ELC provides freeze
protection to −36 °C (−33 °F). The Premixed ELC is
NOTICE recommended for the initial fill of the cooling system.
A commercial heavy-duty antifreeze that meets either The Premixed ELC is also recommended for topping
“ASTM D4985” or “ASTM D6210” specification re- off the cooling system.
quires the SCA concentration to be checked at 500-
hour service intervals.

Perkins recommends a 50% mixture of water and

glycol. This mixture of water and glycol will provide
optimum heavy-duty performance as an antifreeze.
This ratio may be changed to 40% water to 60%
glycol if extra freezing protection is required.
A mixture of SCA inhibitor and water is acceptable
but will not give the same level of corrosion, boiling
and, freezing protection as ELC. Perkins
recommends a 6 percent to 8 percent concentration
of SCA in those cooling systems. Distilled water or
deionized water is preferred.
SEBU8337-03 51
Maintenance Section
Fluid Recommendations

Containers of several sizes are available. Consult

your Perkins dealer or your Perkins distributor for the NOTICE
part numbers. Care must be taken to ensure that all fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and the repair of the
ELC Cooling System Maintenance product. Be prepared to collect the fluid with suitable
containers before opening any compartment or disas-
Correct additions to the Extended Life sembling any component containing fluids.
Coolant Dispose of all fluids according to local regulations
and mandates.
NOTICE
Use only Perkins products for pre-mixed coolants. 1. Drain the coolant into a suitable container.
Mixing Extended Life Coolant with other products re- 2. Dispose of the coolant according to local
duces the Extended Life Coolant service life. Failure regulations.
to follow the recommendations can reduce cooling
system components life unless appropriate corrective 3. Fill the cooling system with a 33 percent solution of
action is performed. Perkins ELC and operate the engine, ensure that
To maintain the correct balance between the the thermostat opens. Stop the engine and allow
antifreeze and the additives, you must maintain the the engine to cool. Drain the coolant.
recommended concentration of ELC. Lowering the
proportion of antifreeze lowers the proportion of Note: Use distilled or deionized water in the solution.
additive. Lowering the ability of the coolant to protect
the system will form pitting, from cavitation, from 4. Again, fill the cooling system with a 33 percent
erosion, and from deposits. solution of Perkins ELC and operate the engine
ensure that the thermostat opens. Stop the engine
NOTICE and allow to cool.
Do not use a conventional coolant to top-off a cooling
system that is filled with Extended Life Coolant 5. Drain the cooling system.
(ELC).
NOTICE
Do not use supplemental coolant additive (SCA). Incorrect or incomplete flushing of the cooling system
can result in damage to copper and other metal
components.
ELC Cooling System Cleaning
Note: If the cooling system is already using ELC, NOTICE
cleaning agents are not required to be used at the Most commercial cooling system cleaning agents are
specified coolant change interval. Cleaning agents corrosive and their use is not recommended by
are only required if the system has been Perkins.
contaminated by the addition of some other type of
coolant or by cooling system damage. 6. Fill the cooling system with the Perkins Premixed
Clean water is the only cleaning agent that is ELC. Operate the engine. Ensure that all coolant
required when ELC is drained from the cooling valves open then stop the engine. When cool
system. check the coolant level.
Before the cooling system is filled, the heater control ELC Cooling System Contamination
(if equipped) must be set to the HOT position. Refer
to the OEM to set the heater control. After the cooling
system is drained and the cooling system is refilled, NOTICE
operate the engine until the coolant level reaches the Mixing ELC with other products reduces the effective-
normal operating temperature and until the coolant ness of the ELC and shortens the ELC service life.
level stabilizes. As needed, add the coolant mixture Use only Perkins products for premixed or concen-
to fill the system to the specified level. trate coolants. Failure to follow these recommenda-
tions can result in shortened cooling system
Changing to Perkins ELC component life.

ELC cooling systems can withstand contamination to

To change from heavy-duty antifreeze to the Perkins a maximum of 10 percent of conventional heavy-duty
ELC, perform the following steps: antifreeze or SCA. If the contamination exceeds ten
percent of the total system capacity, perform ONE of
the following procedures:
52 SEBU8337-03
Maintenance Section
Fluid Recommendations

• Drain the cooling system into a suitable container. Use the equation that is in Table 12 to determine the
Dispose of the coolant according to local amount of Perkins SCA that is required when the
regulations. Flush the system with a 5 to 10 cooling system is initially filled.
percent solution of Perkins ELC. Fill the system Table 12
with the Perkins ELC. Equation For Adding The SCA To The Heavy-Duty Coolant At
The Initial Fill
• Maintain the system as a conventional Heavy-
Duty Coolant. Treat the system with an SCA. V × 0.07 = X
Change the coolant at the interval that is V is the total volume of the cooling system.
recommended for the conventional Heavy-Duty
Coolant. X is the amount of SCA that is required.

Commercial Heavy-Duty Antifreeze and Table 13 is an example for using the equation that is
SCA in Table 12 .
Table 13

NOTICE Example Of The Equation For Adding The SCA To The Heavy-
Commercial Heavy-Duty Coolant which contains Duty Coolant At The Initial Fill
Amine as part of the corrosion protection system
must not be used. Total Volume of the Multiplication Amount of SCA
Cooling System (V) Factor that is Required (X)

15 L (4 US gal) × 0.07 1.05 L (35.5 oz)

NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature Adding The SCA to The Heavy-Duty
regulators help to maintain the engine coolant at the
correct operating temperature. Cooling system prob- Coolant For Maintenance
lems can develop without water temperature
regulators. Heavy-duty antifreeze of all types REQUIRE periodic
additions of an SCA.
Check the glycol concentration to ensure adequate Test the antifreeze periodically for the concentration
protection against boiling or freezing. Perkins of SCA. For the interval, refer to the Operation and
recommends the use of a refractometer for checking Maintenance Manual, “Maintenance Interval
the glycol concentration. A hydrometer should not be Schedule” (Maintenance Section). Test the
used. concentration of SCA.
Perkins engine cooling systems should be tested at Additions of SCA are based on the results of the test.
500-hour intervals for the concentration of The size of the cooling system determines the
Supplemental Coolant Additive (SCA). amount of SCA that is needed.
Additions of SCA are based on the results of the test. Use the equation that is in Table 14 to determine the
An SCA that is liquid may be needed at 500-hour amount of Perkins SCA that is required, if necessary:
intervals.
Table 14

NOTICE Equation For Adding The SCA To The Heavy-Duty Coolant

Do not mix types and brands of coolant. For Maintenance
V × 0.023 = X
Do not mix brands and types of SCAs.
V is the total volume of the cooling system.
Do not mix SCAs and Extenders.
X is the amount of SCA that is required.
Only use SCAs or Extender approved by coolant
manufacturer and compatible with coolant.
Table 15 is an example for using the equation that is
in Table 14 .
Table 15
Adding the SCA to Heavy-Duty Coolant
Example Of The Equation For Adding The SCA To The Heavy-
at the Initial Fill Duty Coolant For Maintenance
Coolants conforming to ASTM D4985 and not Total Volume of the Multiplication Amount of SCA
conforming D6210 require the addition of SCA at Cooling System (V) Factor that is Required (X)
initial fill. Read the label or the instructions that are
provided by the OEM of the product. 15 L (4 US gal) × 0.023 0.35 L (11.7 oz)
SEBU8337-03 53
Maintenance Section
Fluid Recommendations

Cleaning the System of Heavy-Duty Engine Manufacturers Association (EMA)

Antifreeze Oils
Note: Before corrosion inhibitors can be effective the The “Engine Manufacturers Association
cooling system must be free from rust, scale and Recommended Guideline on Diesel Engine Oil” is
deposits. recognized by Perkins. For detailed information
about this guideline, see the latest edition of EMA
• Drain the cooling system. publication, “EMA DHD -1”.

• Before filling the cooling system with acceptable API Oils

quality water, pre-dissolve the cleaning agent in
the water. Use a non-foaming detergent to clean The Engine Oil Licensing and Certification System by
oil contamination, consult your Perkins dealer for the American Petroleum Institute (API) is recognized
suitable product. by Perkins. For detailed information about this
system, see the latest edition of the “API publication
No. 1509”. Engine oils that bear the API symbol are
NOTICE authorized by API.
Most commercial cooling system cleaning agents are
corrosive and their use is not recommended by
Perkins.
The cooling system must be thoroughly flushed with
clean water after using cleaning agents.
Cleaning agents for marine or industrial cooling sys-
tem must not be used. These cleaning agents are
very aggressive and can cause damage to cooling
system components.

• Run the engine for approximately 30 minutes and

then leave the engine to cool down.
• Take a sample of the solution from the cooling
system, drain the system. Illustration 21 g00546535
Typical API symbol
• Allow the sample to sit for at least 30 minutes and
check for signs of oil and deposits. If oil and Diesel engine oils CC, CD, CD-2, and CE have not
deposits are still present, repeat the procedure. been API authorized classifications since January 1,
1996. Table 16 summarizes the status of the
• Flush the system with clean water. classifications.
Table 16
• Fill the system with new coolant.
API Classifications

i09711165 Current Obsolete

CH-4, CI-4, CK-4 CE, CC, CD
Fluid Recommendations - CD-2 (1)
(1) The oil CD-2 is for a two-cycle diesel engine. Perkins does not
sell engines that utilize CD-2 oil.
General Lubricant Information
Because of government regulations regarding the
certification of exhaust emissions from the engine,
the lubricant recommendations must be followed.
• EMA Engine Manufacturers Association

• API American Petroleum Institute

• SAE Society Of Automotive Engineers Inc.
Refer to Perkins Diesel Engines Fluids
Recommendations, M0113102 for additional
information that relates to oil.
54 SEBU8337-03
Maintenance Section
Fluid Recommendations

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

Engine Oil
Commercial Oils
Illustration 22 g00799818
The performance of commercial diesel engine oils is
based on American Petroleum Institute (API) (Y) TBN by “ASTM D2896”
classifications. These API classifications are (X) Percentage of fuel sulfur by weight
developed to provide commercial lubricants for a (1) TBN of new oil
(2) Change the oil when the TBN deteriorates to 50 percent of the
broad range of diesel engines that operate at various original TBN.
conditions.
Only use commercial oils that meet the following Use the following guidelines for fuel sulfur levels that
classifications: exceed 1.5 percent:

• API CK-4 CH-4 CI-4 CI-4 PLUS • Choose an oil with the highest TBN that meets
one of the recommended classifications
• ACEA E9 ACEA E7
• Reduce the oil change interval. Base the oil
• ECF-1a ECF-2 ECF-3 change interval on the oil analysis. Ensure that the
oil analysis includes the condition of the oil and a
Some commercial oils that meet the API wear metal analysis.
classifications may require reduced oil change
intervals. To determine the oil change interval, Excessive piston deposits can be produced by an oil
closely monitor the condition of the oil and perform a with a high TBN. These deposits can lead to a loss of
wear metal analysis. control of the oil consumption and to the polishing of
the cylinder bore.
NOTICE
Failure to follow these oil recommendations can NOTICE
cause shortened engine service life due to deposits Operating Direct Injection (DI) diesel engines with
and/or excessive wear. fuel sulphur levels over 0.5 percent will require short-
ened oil change intervals to help maintain adequate
wear protection.
Total Base Number (TBN) and Fuel Sulfur
Levels for Direct Injection (DI) Diesel Table 17
Engines Percentage of Sulfur in the Oil change interval
fuel
The Total Base Number (TBN) for an oil depends on Lower than 0.5 Normal
the fuel sulfur level. For direct injection engines that
use distillate fuel, the minimum TBN of the new oil 0.5 to 1.0 0.75 of normal
must be 10 times the fuel sulfur level. The TBN is
defined by “ASTM D2896”. The minimum TBN of the Greater than 1.0 0.50 of normal
oil is 5 regardless of fuel sulfur level. Illustration 22
demonstrates the TBN.
Lubricant Viscosity Recommendations
for Direct Injection (DI) Diesel Engines
The correct SAE viscosity grade of oil is determined
by the minimum ambient temperature during cold
engine start-up, and the maximum ambient
temperature during engine operation.
SEBU8337-03 55
Maintenance Section
Fluid Recommendations

Refer to Table 18 (minimum temperature) to The process that is used to make re-refined base
determine the required oil viscosity for starting a cold stock oil should adequately remove all wear metals
engine. that are in the used oil and all the additives that are in
the used oil. The process that is used to make re-
Refer to Table 18 (maximum temperature) to select refined base stock oil generally involves the process
the oil viscosity for engine operation at the highest of vacuum distillation and hydrotreating the used oil.
ambient temperature that is anticipated. Filtering is adequate for the production of high
quality, re-refined base stock oil.
Generally, use the highest oil viscosity that is
available to meet the requirement for the temperature Lubricants for Cold Weather
at start-up.
Table 18 When an engine is started and an engine is operated
Engine Oil Viscosity in ambient temperatures below −20 °C (−4 °F), use
multigrade oils that are capable of flowing in low
EMA LRG-1 Ambient Temperature temperatures.
API
Viscosity Grade Minimum Maximum These oils have lubricant viscosity grades of SAE 0W
or SAE 5W.
SAE 0W40 −40 °C (−40 °F) 40 °C (104 °F)
When an engine is started and operated in ambient
SAE 5W40 −30 °C (−22 °F) 50 °C (122 °F) temperatures below −30 °C (−22 °F), use a synthetic
−18 °C (0 °F) 40 °C (104 °F)
base stock multigrade oil with an 0W viscosity grade
SAE 10W30
or with a 5W viscosity grade. Use an oil with a pour
SAE 15W40 −10 °C (14 °F) 50 °C (122 °F) point that is lower than −50 °C (−58 °F).

Aftermarket Oil Additives

Synthetic Base Stock Oils
Perkins does not recommend the use of aftermarket
Synthetic base oils are acceptable for use in these additives in oil. It is not necessary to use aftermarket
engines if these oils meet the performance additives to achieve the engine's maximum service
requirements that are specified for the engine. life or rated performance. Fully formulated, finished
oils consist of base oils and of commercial additive
Synthetic base oils generally perform better than packages. These additive packages are blended into
conventional oils in the following two areas: the base oils at precise percentages to help provide
finished oils with performance characteristics that
• Synthetic base oils have improved flow at low meet industry standards.
temperatures especially in arctic conditions.
There are no industry standard tests that evaluate
• Synthetic base oils have improved oxidation the performance or the compatibility of aftermarket
stability especially at high operating temperatures. additives in finished oil. Aftermarket additives may
not be compatible with the finished oil's additive
Some synthetic base oils have performance package, which could lower the performance of the
characteristics that enhance the service life of the oil. finished oil. The aftermarket additive could fail to mix
Perkins does not recommend the automatic with the finished oil. This could produce sludge in the
extending of the oil change intervals for any type of crankcase. Perkins discourages the use of
oil. aftermarket additives in finished oils.
To achieve the best performance from a Perkins
Re-refined Base Stock Oils engine, conform to the following guidelines:
Re-refined base stock oils are acceptable for use in • Select the correct oil, or a commercial oil that
Perkins engines if these oils meet the performance meets the “EMA Recommended Guideline on
requirements that are specified by Perkins. Re- Diesel Engine Oil” or the recommended API
refined base stock oils can be used exclusively in
finished oil or in a combination with new base stock classification.
oils. The US military specifications and the
specifications of other heavy equipment • Refer to table 18 to find the correct oil viscosity
manufacturers also allow the use of re-refined base grade for your engine.
stock oils that meet the same criteria.
• At the specified interval, service the engine. Use
new oil and install a new oil filter.

• Perform maintenance at the intervals that are

specified in the Operation and Maintenance
Manual, “Maintenance Interval Schedule”.
56 SEBU8337-03
Maintenance Section
Fluid Recommendations

Oil analysis
Some engines may be equipped with an oil sampling
valve. If oil analysis is required the oil sampling valve
is used to obtain samples of the engine oil. The oil
analysis will complement the preventive maintenance
program.
The oil analysis is a diagnostic tool that is used to
determine oil performance and component wear
rates. Contamination can be identified and measured
through by using an oil analysis. The oil analysis
includes the following tests:

• The Wear Rate Analysis monitors the wear of the

engine's metals. The amount of wear metal and
type of wear metal that is in the oil is analyzed.
The increase in the rate of engine wear metal in
the oil is as important as the quantity of engine
wear metal in the oil.

• Tests are conducted to detect contamination of the

oil by water, glycol, or fuel.

• The Oil Condition Analysis determines the loss of

the oil's lubricating properties. An infrared analysis
is used to compare the properties of new oil to the
properties of the used oil sample. This analysis
allows technicians to determine the amount of
deterioration of the oil during use. This analysis
also allows technicians to verify the performance
of the oil according to the specification during the
entire oil change interval.
SEBU8337-03 57
Maintenance Section
Maintenance Interval Schedule

i09711185 “ Engine Mounts - Inspect“ . . . . . . . . . . . . . . . . . . . 70

Maintenance Interval Schedule “ Engine Oil and Filter - Change“. . . . . . . . . . . . . . . 72

“ Fan Drive Bearing - Lubricate“ . . . . . . . . . . . . . . . 77
“ Fuel System Primary Filter (Water Separator)
When Required Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 78
“ Battery - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 58 “ Fuel System Secondary Filter - Replace“. . . . . . . 80
“ Battery or Battery Cable - Disconnect“ . . . . . . . . . 60 “ Hoses and Clamps - Inspect/Replace“. . . . . . . . . 82
“ Engine - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 “ Radiator - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . 83
“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . . 71
Every 1000 Service Hours or 1 Year
“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . . 77
“ Electronic Unit Injector - Inspect/Adjust“ . . . . . . . 66
“ Severe Service Application - Check“ . . . . . . . . . . 83
Every 2000 Service Hours
Daily
“ Alternator - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 58
“ Cooling System Coolant Level - Check“. . . . . . . . 65
“ Water Pump - Inspect“. . . . . . . . . . . . . . . . . . . . . . 86
“ Driven Equipment - Check“ . . . . . . . . . . . . . . . . . . 66
“ Engine Air Cleaner Service Indicator - Inspect“ . . 68
Every 3000 Service Hours or 2
Years
“ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . . 71
“ Cooling System Coolant (Commercial Heavy-Duty)
“ Fuel System Primary Filter/Water Separator - - Change“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Drain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
“ Cooling System Water Temperature Regulator -
“ Walk-Around Inspection“ . . . . . . . . . . . . . . . . . . . . 85 Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Every Week “ Crankshaft Vibration Damper - Inspect“ . . . . . . . . 66

“ Engine Protective Devices - Check“ . . . . . . . . . . . 75
“ Jacket Water Heater - Check“. . . . . . . . . . . . . . . . 82
“ Engine Speed/Timing Sensors - Check/Clean/
Every 250 Service Hours or 1 Year Calibrate“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

“ Battery Electrolyte Level - Check“ . . . . . . . . . . . . 59 “ Turbocharger - Inspect“ . . . . . . . . . . . . . . . . . . . . . 84

“ Fuel Tank Water and Sediment - Drain“ . . . . . . . . 81 Every 5000 Service Hours
Initial 500 Service Hours “ Starting Motor - Inspect“ . . . . . . . . . . . . . . . . . . . . 84

“ Engine Valve Lash - Inspect/Adjust“ . . . . . . . . . . . 76 Every 6000 Service Hours

Every 500 Service Hours “ Overhaul Considerations“ . . . . . . . . . . . . . . . . . . . 83

“ Belts - Inspect/Adjust/Replace“. . . . . . . . . . . . . . . 60 Every 6000 Service Hours or 3

“ Engine Valve Lash - Inspect/Adjust“ . . . . . . . . . . . 76 Years
“ Cooling System Coolant (ELC) - Change“ . . . . . . 63
Every 500 Service Hours or 1 Year
“ Aftercooler Core - Clean/Test“ . . . . . . . . . . . . . . . 58 Every 12 000 Service Hours or 6
“ Engine Air Cleaner Element (Single Element) - Years
Inspect/Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
“ Overhaul Considerations“ . . . . . . . . . . . . . . . . . . . 83
“ Engine Crankcase Breather - Replace“ . . . . . . . . 69
58 SEBU8337-03
Maintenance Section
Aftercooler Core - Clean/Test

i02578388 i02322311

Aftercooler Core - Clean/Test Alternator - Inspect

(Air-To-Air Aftercooler)
Perkins recommends a scheduled inspection of the
alternator. Inspect the alternator for loose
Note: Adjust the frequency of cleaning according to connections and correct battery charging. Check the
the effects of the operating environment. ammeter (if equipped) during engine operation in
order to ensure correct battery performance and/or
Inspect the cooling air side of the aftercooler for correct performance of the electrical system. Make
these items: damaged fins, corrosion, dirt, grease, repairs, as required.
insects, leaves, oil and other debris. Clean the
cooling air side of the aftercooler, if necessary. Check the alternator and the battery charger for
correct operation. If the batteries are correctly
For air-to-air aftercoolers, use the same methods that charged, the ammeter reading should be very near
are used for cleaning the outside of radiators. 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
Personal injury can result from air pressure. engine is not run for long periods of time or if the
engine is run for short periods, the batteries may not
Personal injury can result without following prop- fully charge. A battery with a low charge will freeze
er procedure. When using pressure air, wear a more easily than a battery with a full charge.
protective face shield and protective clothing.
i01878164
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Battery - Replace
Pressurized air is the preferred method for removing
loose debris. Hold the nozzle approximately 6 mm
(0.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes. Batteries give off combustible gases which can
explode. A spark can cause the combustible
Pressurized water may also be used for cleaning. gases to ignite. This can result in severe personal
The maximum water pressure for cleaning purposes injury or death.
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
Use a degreaser and steam for removal of oil and der to help prevent electrical arcs and/or sparks
grease. Wash the core with detergent and hot water. near batteries. Do not smoke when batteries are
Thoroughly rinse the core with clean water. serviced.
After cleaning, start the engine. Run the engine for
two minutes. This will help in the removal of debris
and drying of the core. Stop the engine. Inspect the
core for cleanliness. Repeat the cleaning, if
necessary. The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
Inspect the fins for damage. Bent fins may be opened tery cover should be removed before any servic-
with a “comb”. ing is attempted.
Inspect these items for good condition: welds, Removing the battery cables or the batteries with
mounting brackets, air lines, connections, clamps the cover in place may cause a battery explosion
and seals. Make repairs, if necessary. resulting in personal injury.

1. Switch the engine to the OFF position. Remove all

electrical loads.
2. Turn off any battery chargers. Disconnect any
battery chargers.
SEBU8337-03 59
Maintenance Section
Battery - Replace

3. The NEGATIVE “-” cable connects the NEGATIVE 2. Turn off any battery chargers. Disconnect any
“-” battery terminal to the NEGATIVE “-” terminal battery chargers.
on the starter motor. Disconnect the cable from the
3. Remove the NEGATIVE “-” terminal connection on
NEGATIVE “-” battery terminal.
the battery. Ensure that the terminal cannot
4. The POSITIVE “+” cable connects the POSITIVE contact the terminal on the battery.
“+” battery terminal to the POSITIVE “+” terminal
4. Remove the POSITIVE “+” terminal connection on
on the starting motor. Disconnect the cable from
the battery.
the POSITIVE “+” battery terminal.
Note: Always recycle a battery. Never discard a
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
battery. Return used batteries to an appropriate
recycling facility.
recycling facility.
5. Remove the used battery.
5. Remove the used battery.
6. Install the new battery.
6. Install the new battery.
Note: Before the terminal connections are
Note: Before the cables are connected, ensure that
connected, ensure that the engine start switch is
the engine start switch is OFF. OFF.
7. Connect the cable from the starting motor to the 7. Connect the POSITIVE “+” connection to the
POSITIVE “+” battery terminal.
POSITIVE “+” terminal on the battery.
8. Connect the cable from the NEGATIVE “-” terminal
8. Connect the NEGATIVE “-” terminal connection to
on the starter motor to the NEGATIVE “-” battery the NEGATIVE “-” terminal on the battery.
terminal.
i02563861
i08194371

Battery - Replace Battery Electrolyte Level -

Check

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

when the engine is run for short periods, the batteries
Batteries give off combustible gases which can may not fully recharge. Ensure a full charge in order
explode. A spark can cause the combustible to help prevent the battery from freezing. If batteries
gases to ignite. This can result in severe personal are correctly charged, the ammeter reading should
injury or death. be very near zero, when the engine is in operation.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are All lead-acid batteries contain sulfuric acid which
serviced. can burn the skin and clothing. Always wear a
face shield and protective clothing when working
on or near batteries.

The battery cables or the batteries should not be 1. Remove the filler caps. Maintain the electrolyte
removed with the battery cover in place. The bat- level to the “FULL” mark on the battery.
tery cover should be removed before any servic- If the addition of water is necessary, use distilled
ing is attempted.
water. If distilled water is not available use clean
Removing the battery cables or the batteries with water that is low in minerals. Do not use artificially
the cover in place may cause a battery explosion softened water.
resulting in personal injury.
2. Check the condition of the electrolyte with a
suitable battery tester.
1. Ensure that the engine is stopped. Refer to this
manual, “Stopping the Engine”. Ensure that all 3. Install the caps.
electrical loads are removed. 4. Keep the batteries clean.
60 SEBU8337-03
Maintenance Section
Battery or Battery Cable - Disconnect

Clean the battery case with one of the following i02784753

cleaning solutions:
Belts - Inspect/Adjust/Replace
• A mixture of 0.1 kg (0.2 lb) of washing soda or
baking soda and 1 L (1 qt) of clean water

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L Inspection

(1 qt) of clean water
Inspect the alternator belt and the fan drive belts for
Thoroughly rinse the battery case with clean wear and for cracking. Replace the belts if the belts
water. are not in good condition.

Use a fine grade of sandpaper to clean the Check the belt tension according to the information in
terminals and the cable clamps. Clean the items Systems Operation, Testing and Adjusting, “Belt
until the surfaces are bright or shiny. DO NOT Tension Chart”.
remove material excessively. Excessive removal Slippage of loose belts can reduce the efficiency of
of material can cause the clamps to not fit the driven components. Vibration of loose belts can
properly. Coat the clamps and the terminals with a cause unnecessary wear on the following
suitable petroleum jelly. components:

• Belts
i08246088
• Pulleys
Battery or Battery Cable -
• Bearings
Disconnect

The battery cables or the batteries should not be

removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.

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

ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Turn off any battery chargers. Disconnect any
battery chargers.
3. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.
4. Tape the leads to help prevent accidental starting.
5. Proceed with necessary system repairs. Reverse
the steps to reconnect all cables.
SEBU8337-03 61
Maintenance Section
Belts - Inspect/Adjust/Replace

If the belts are too tight, unnecessary stress is placed 5. Tighten the setscrew for the adjustment link (1)
on the components. This reduces the service life of securely. Tighten alternator pivot bolt (2) securely.
the components.
6. Reinstall the belt guard.
Replacement If new alternator belts are installed, check the
tension of the alternator belt again after 10
For applications that require multiple drive belts, minutes of engine operation at the rated rpm.
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new 7. Remove the belt guard and check the belt tension.
drive belt to carry more load because the older drive
When the correct belt tension is obtained, fit the
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail. belt guard.

Alternator Belt Adjustment Adjustment of the Fan Drive Belt

Illustration 24 g01402065

1. Remove the belt guard.

2. Loosen the large locknut (3) and turn the
adjustment screw (4) until the correct belt tension
is obtained.
Illustration 23 g01391209
3. Tighten the large locknut (3) securely and recheck
1. Remove the belt guard. the belt tension.

2. Loosen alternator pivot bolt (2) . 4. If the belt tension is correct, loosen the adjustment
screw (3) in order to release the tension.
3. Loosen the setscrew for the adjustment link (1).
5. Reinstall the belt guard.
4. Move the assembly in order to increase or
decrease the belt tension. Refer to Systems If new alternator belts are installed, check the
Operation, Testing and Adjusting, “Belt Tension tension of the alternator belt again after 10
Chart”. minutes of engine operation at the rated rpm.
62 SEBU8337-03
Maintenance Section
Cooling System Coolant (Commercial Heavy-Duty) - Change

6. Remove the belt guard and check the belt tension. Drain
When the correct belt tension is obtained, fit the
belt guard.

i09711115 Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
Cooling System Coolant stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
(Commercial Heavy-Duty) - pressure cap slowly in order to relieve the
pressure.
Change
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly to
NOTICE relieve any pressure. Remove the cooling system
Care must be taken to ensure that fluids are con- filler cap.
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. 2. Open the drain cock or remove the drain plug on
Be prepared to collect the fluid with suitable contain- the radiator.
ers before opening any compartment or disassem-
bling any component containing fluids. Allow the coolant to drain.
Dispose of all fluids according to Local regulations
and mandates. NOTICE
Dispose of used engine coolant or recycle. Various
methods have been proposed to reclaim used cool-
ant for reuse in engine cooling systems. The full distil-
NOTICE lation procedure is the only method acceptable by
Keep all parts clean from contaminants. Perkins to reclaim the coolant.
Contaminants may cause rapid wear and shortened
component life. For information regarding the disposal and the
recycling of used coolant, consult your Perkins dealer
Clean the cooling system and flush the cooling or your Perkins distributor.
system before the recommended maintenance
interval if the following conditions exist:
Flush
• The engine overheats frequently.
1. Flush the cooling system with clean water to
• Foaming of the coolant is observed. remove any debris.
• The oil has entered the cooling system and the 2. Close the drain cock or install the drain plug on the
coolant is contaminated. radiator.
• The fuel has entered the cooling system and the NOTICE
coolant is contaminated. Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Note: When the cooling system is cleaned, only
clean water is needed when the coolant is drained Cooling system air locks may result in engine
and replaced. damage.

Note: Inspect the water pump and the water

temperature regulator after the cooling system has 3. Fill the cooling system with clean water. Install the
been drained. This is a good opportunity to replace cooling system filler cap.
the water pump, the water temperature regulator, and
4. Start and run the engine until the water
the hoses, if necessary.
temperature regulator opens and the fluid levels
decreases in the header tank.
SEBU8337-03 63
Maintenance Section
Cooling System Coolant (ELC) - Change

5. Stop the engine and allow the engine to cool. 5. Clean the cooling system filler cap and inspect the
Loosen the cooling system filler cap slowly to gasket. If the gasket is damaged, discard the old
relieve any pressure. Remove the cooling system filler cap and install a new filler cap. If the gasket is
filler cap. Open the drain cock or remove the drain not damaged, use a suitable pressurizing pump to
plug on the radiator. Allow the water to drain. Flush pressure test the filler cap. The correct pressure is
the cooling system with clean water. stamped on the face of the filler cap. If the filler
cap does not retain the correct pressure, install a
Fill new filler cap.
6. Start the engine. Inspect the cooling system for
1. Close the drain cock or install the drain plug on the
leaks and for correct operating temperature.
radiator.
i02579635
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks. Cooling System Coolant (ELC)
Cooling system air locks may result in engine - Change
damage.

2. Fill the cooling system with coolant. Refer to the NOTICE

Operation and Maintenance Manual, “Fluid Care must be taken to ensure that fluids are con-
Recommendations” for more information on tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
cooling system specifications. Do not install the Be prepared to collect the fluid with suitable contain-
cooling system filler cap. ers before opening any compartment or disassem-
bling any component containing fluids.
3. Start and run the engine for 1 minute to purge the
air from the cavities of the engine block. Stop the Dispose of all fluids according to Local regulations
engine. and mandates.
4. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the NOTICE
pipe for filling. If necessary, repeat step 3. Maintain Keep all parts clean from contaminants.
the coolant level in the expansion bottle (if
equipped) at the correct level. Contaminants may cause rapid wear and shortened
component life.

Clean the cooling system and flush the cooling

system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.

• Foaming of the coolant is observed.

• The oil has entered the cooling system and the
coolant is contaminated.

• The fuel has entered the cooling system and the

coolant is contaminated.

Note: When the cooling system is cleaned, only

Illustration 25 g00103639
clean water is needed when the ELC is drained and
replaced.
Filler cap
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
64 SEBU8337-03
Maintenance Section
Cooling System Coolant (ELC) - Change

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

Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain cock or remove
Pressurized System: Hot coolant can cause seri- the drain plug on the radiator. Allow the water to
ous burns. To open the cooling system filler cap, drain. Flush the cooling system with clean water.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the Fill
pressure.
1. Close the drain cock or install the drain plug on the
radiator.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in NOTICE
order to relieve any pressure. Remove the cooling Do not fill the cooling system faster than 5 L
system filler cap. (1.3 US gal) per minute to avoid air locks.
2. Open the drain cock or remove the drain plug on Cooling system air locks may result in engine
the radiator. damage.
Allow the coolant to drain.
2. Fill the cooling system with Extended Life Coolant
NOTICE (ELC). Refer to the Operation and Maintenance
Dispose of used engine coolant or recycle. Various Manual, “Fluid Recommendations” topic
methods have been proposed to reclaim used cool- (Maintenance Section) for more information on
ant for reuse in engine cooling systems. The full distil-
lation procedure is the only method acceptable by cooling system specifications. Do not install the
Perkins to reclaim the coolant. cooling system filler cap.
3. Start and run the engine for one minute in order to
For information regarding the disposal and the purge the air from the cavities of the engine block.
recycling of used coolant, consult your Perkins dealer Stop the engine.
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. If necessary, repeat step 3. Maintain
1. Flush the cooling system with clean water in order the coolant level in the expansion bottle (if
to remove any debris. equipped) at the correct level.

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

radiator.

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

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

cooling system filler cap.
4. Start and run the engine until the water
temperature regulator opens and the fluid levels
Illustration 26 g00103639
decreases in the header tank.
Filler cap
SEBU8337-03 65
Maintenance Section
Cooling System Coolant Level - Check

5. Clean the cooling system filler cap and inspect the

gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket is
not damaged, use a suitable pressurizing pump in
order to pressure test the filler cap. The correct
pressure is stamped on the face of the filler cap. If
the filler cap does not retain the correct pressure,
install a new filler cap.
6. Start the engine. Inspect the cooling system for
leaks and for correct operating temperature.

i01197583

Cooling System Coolant Level Illustration 28 g00103639

- Check Typical filler cap gaskets

3. Clean the cooling system filler cap and check the

Check the coolant level when the engine is stopped condition of the filler cap gaskets. Replace the
and cool. cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks.

i02573904

Cooling System Water

Temperature Regulator -
Replace

Replace the water temperature regulator before the

water temperature regulator fails. This is a
recommended preventive maintenance practice.
Illustration 27 g00285520
Replacing the water temperature regulator reduces
Cooling system filler cap the chances for unscheduled downtime.
A water temperature regulator that fails in a partially
opened position can cause overheating or
overcooling of the engine.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, A water temperature regulator that fails in the closed
stop the engine and wait until the cooling system position can cause excessive overheating. Excessive
components are cool. Loosen the cooling system overheating could result in cracking of the cylinder
pressure cap slowly in order to relieve the head or piston seizure problems.
pressure.
A water temperature regulator that fails in the open
position will cause the engine operating temperature
1. Remove the cooling system filler cap slowly in to be too low during partial load operation. Low
order to relieve pressure. engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
2. Maintain the coolant level within 13 mm (0.5 inch) cylinders. This excessive carbon buildup could result
of the bottom of the filler pipe. If the engine is in an accelerated wear of the piston rings and wear of
equipped with a sight glass, maintain the coolant the cylinder liner.
level to the proper level in the sight glass.
Refer to Disassembly and Assembly, “Water
Temperature Regulator Housing - Remove and
Install” for the replacement procedure of the water
temperature regulator, or consult your Perkins
distributor.
66 SEBU8337-03
Maintenance Section
Crankshaft Vibration Damper - Inspect

Note: If only the water temperature regulators are Refer to the Service Manual or consult your Perkins
replaced, drain the coolant from the cooling system distributor for information about damper replacement.
to a level that is below the water temperature
regulator housing. i02151646

i02573905 Driven Equipment - Check

Crankshaft Vibration Damper -
Inspect Refer to the OEM specifications for more information
on the following maintenance recommendations for
the driven equipment:
Damage to the crankshaft vibration damper or failure • Inspection
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to the • Adjustment
crankshaft and to other engine components. A
damper that is damaged can cause excessive gear • Lubrication
train noise at variable points in the speed range.
• Other maintenance recommendations
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the Perform any maintenance for the driven equipment
engine. which is recommended by the OEM.

Visconic Damper i02784833

The visconic damper has a weight that is located Electronic Unit Injector -
inside a fluid filled case. The weight moves in the Inspect/Adjust
case in order to limit torsional vibration.
Inspect the damper for evidence of fluid leaks. If a
fluid leak is found, determine the type of fluid. The
fluid in the damper is silicone. Silicone has the
following characteristics: transparent, viscous and
smooth. Be sure the engine cannot be started while this
maintenance is being performed. To prevent pos-
If the fluid leak is oil, inspect the crankshaft seals for sible injury, do not use the starting motor to turn
leaks. If a leak is observed, replace the crankshaft the flywheel.
seals.
Hot engine components can cause burns. Allow
Inspect the damper and repair or replace the damper additional time for the engine to cool before
for any of the following reasons: measuring/adjusting the unit injectors.
• The damper is dented, cracked, or leaking. The electronic unit injectors use high voltage.
Disconnect the unit injector enable circuit con-
• The paint on the damper is discolored from heat. nector in order to prevent personal injury. Do not
come in contact with the injector terminals while
• The engine has had a failure because of a broken the engine is running.
crankshaft.
The operation of Perkins engines with improper
• Analysis of the oil has revealed that the front main adjustments of the electronic unit injector can reduce
bearing is badly worn. engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
• There is a large amount of gear train wear that is component life.
not caused by a lack of oil.
Only qualified service personnel should perform this
• The temperature of the damper fluid is too high. maintenance. Refer to the following topics for your
engine for the correct procedure: Refer to the
Systems Operation, Testing and Adjusting,
“Electronic Unit Injector - Test” for the test procedure,
and Systems Operation, Testing and Adjusting,
“Electronic Unit Injector - Adjust” for the correct
procedure for adjusting the injectors.
SEBU8337-03 67
Maintenance Section
Engine - Clean

i02568158
NOTICE
Never service the air cleaner element with the engine
Engine - Clean running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Element

Personal injury or death can result from high Note: The air filter system may not have been
voltage. provided by Perkins. The procedure that follows is for
a typical air filter system. Refer to the OEM
Moisture can create paths of electrical information for the correct procedure.
conductivity.
If the air cleaner element becomes plugged, the air
Make sure that the electrical system is OFF. Lock can split the material of the air cleaner element.
out the starting controls and tag the controls “ DO Unfiltered air will drastically accelerate internal
NOT OPERATE”” . engine wear. Refer to the OEM information for the
correct air cleaner elements for your application.

NOTICE • Check the precleaner (if equipped) and the dust

Accumulated grease and oil on an engine is a fire bowl (if equipped) daily for accumulation of dirt
hazard. Keep the engine clean. Remove debris and and debris. Remove any dirt and debris, as
fluid spills whenever a significant quantity accumu- needed.
lates on the engine.
• Operating in dirty conditions may require more
Periodic cleaning of the engine is recommended. frequent service of the air cleaner element.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following • The air cleaner element should be replaced at
benefits: least one time per year. This replacement should
be performed regardless of the number of
• Easy detection of fluid leaks cleanings.
• Maximum heat transfer characteristics Replace the dirty air cleaner elements with clean air
cleaner elements. Before installation, the air cleaner
• Ease of maintenance elements should be thoroughly checked for tears
and/or holes in the filter material. Inspect the gasket
Note: Caution must be used in order to prevent or the seal of the air cleaner element for damage.
electrical components from being damaged by Maintain a supply of suitable air cleaner elements for
excessive water when you clean the engine. Avoid replacement purposes.
electrical components such as the alternator, the
starter, and the Electronic Control Module (ECM). Cleaning the Air Cleaner Element
i02570750 Refer to the OEM information in order to determine
the number of times that the air filter element can be
Engine Air Cleaner Element cleaned. When the air cleaner element is cleaned,
check for rips or tears in the filter material. The air
(Single Element) - Inspect/ cleaner element should be replaced at least one time
per year. This replacement should be performed
Replace regardless of the number of cleanings.

NOTICE
Refer to Operation and Maintenance Manual, Do not tap or strike the air cleaner element.
“Engine Air Cleaner Service Indicator-Inspect”.
Do not wash the primary air cleaner element.
NOTICE Use low pressure (207 kPa; 30 psi maximum) pres-
Never run the engine without an air cleaner element
surised air or vacuum cleaning to clean the primary
installed. Never run the engine with a damaged air
air cleaner element.
cleaner element. Do not use air cleaner elements
with damaged pleats, gaskets or seals. Dirt entering Take extreme care in order to avoid damage to the air
the engine causes premature wear and damage to cleaner elements.
engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet. Do not use air cleaner elements that have damaged
pleats, gaskets or seals.
68 SEBU8337-03
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Refer to the OEM information in order to determine Note: Refer to “Inspecting the Air Cleaner Element”.
the number of times that the air cleaner element can
be cleaned. Do not clean the air filter element more
than three times. The air cleaner element must be Vacuum Cleaning
replaced at least one time per year.
Vacuum cleaning is a good method for removing
Cleaning the air filter element will not extend the life accumulated dirt from the dirty side (outside) of an air
of the air filter element. cleaner element. Vacuum cleaning is especially
useful for cleaning the air cleaner element that will
Visually inspect the air cleaner element before require daily cleaning because of a dry, dusty
cleaning. Inspect air cleaner elements for damage to environment.
the pleats, the seals, the gaskets and the outer cover.
Discard any damaged air cleaner element. Cleaning from the clean side (inside) with
pressurized air is recommended prior to vacuum
Two methods may be used in order to clean the air cleaning the dirty side (outside) of an air cleaner
cleaner element: element.
• Pressurized air Note: Refer to “Inspecting the Air Cleaner Element”.
• Vacuum cleaning Inspecting the Air Cleaner Element
Pressurized Air

Personal injury can result from air pressure.

Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.

Pressurized air can be used to clean primary air

cleaner elements that have not been cleaned more
than three times. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi). Pressurized air will not Illustration 30 g00281693
remove deposits of carbon and oil.
Inspect the clean, dry air cleaner element. Use a 60
watt blue light in a dark room or in a similar facility.
Place the blue light in the air cleaner element. Rotate
the air cleaner element. Inspect the air cleaner
element for tears and/or holes. Inspect the air cleaner
element for light that may show through the filter
material. If it is necessary in order to confirm the
result, compare the air cleaner element to a new air
cleaner element that has the same part number.
Do not use a air cleaner element that has any tears
and/or holes in the filter material. Do not use an air
cleaner element with damaged pleats, gaskets or
seals. Discard damaged air cleaner elements.

i02568159
Illustration 29 g00281692
Engine Air Cleaner Service
Note: When the air cleaner element is cleaned,
always begin with the clean side (inside) in order to Indicator - Inspect
force dirt particles toward the dirty side (outside). (If Equipped)
Aim the air hose so that air flows along the length of
the filter. Follow the direction of the paper pleats in
order to prevent damage to the pleats. Do not aim the Some engines may be equipped with a different
air directly at the face of the paper pleats. service indicator.
SEBU8337-03 69
Maintenance Section
Engine Crankcase Breather - Replace

Some engines are equipped with a differential gauge

for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner housing or in a remote location.

Illustration 31 g00103777
Typical service indicator Illustration 32 g01404179

Observe the service indicator. The air cleaner Typical example

element should be cleaned or the air cleaner element
should be replaced when the following condition 1. Ensure that a suitable container is used in order to
occurs: contain any fluid that may spill. Remove all dirt and
• The red piston locks in the visible position. oil from the outside of the breather assembly.
Remove the connection for the drain (1).
i02784851

Engine Crankcase Breather -

Replace

Crankcase Breather
NOTICE
Ensure that the components of the breather assem-
bly are installed in the correct position. If installed in-
correctly, engine damage can result.

Illustration 33 g01404604
Typical example
70 SEBU8337-03
Maintenance Section
Engine Mounts - Inspect

2. Unlatch the clips (2) that secure the filter bowl (6).

Illustration 35 g01404934
Typical example

Note: The breather had an indicator (7). If the

indicator is operated then the filter element must be
replaced. The indicator will need to be reset. Remove
the plastic cover and push down the red indicator.
Install the plastic cover.

Open Breather
The open breather may be installed on some engine
applications. Ensure that breather hose assembly is
installed correctly. Ensure that the breather hose is
not damaged or restricted.

i07819538

Engine Mounts - Inspect

Illustration 34 g01404613
Note: The engine mounts may not have been
Typical example supplied by Perkins. Refer to the Original Equipment
Manufacturer (OEM) information for further details on
3. Remove the filter bowl and remove the filter the engine mounts and the correct bolt torque.
element (5). Remove the O ring seal (4) with the
filter element. Inspect the engine mounts for deterioration and for
correct bolt torque. Excessive engine vibration can
4. Remove the main O ring seal (3). Clean the filter be caused by the following conditions:
bowl.
• Incorrect mounting of the engine
5. Install a new O ring seal (3). Install the new O ring
seal (4) on the new filter element (5). Install the • Deterioration of the engine mounts
filter element into the filter bowl (6).
• Loose engine mounts
6. Align the filter element and the filter bowl. Install
Any engine mount that shows deterioration should be
the filter bowl to the top of the breather. Connect replaced. Refer to the OEM information for the
the drain (1). recommended torques.
SEBU8337-03 71
Maintenance Section
Engine Oil Level - Check

When the engine mounts are supplied by Perkins the

maintenance procedure will be supplied in the
Disassembly and Assembly manual for your engine.

i02790188

Engine Oil Level - Check

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

Illustration 37 g01393934
Typical example

NOTICE
Operating your engine when the oil level is above the
“High” mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power.
Illustration 36 g01165836
(Y) “Low” mark. (X) “High” mark.
2. Remove the oil filler cap (1) and add oil, if
necessary. Clean the oil filler cap. Install the oil
NOTICE filler cap.
Perform this maintenance with the engine stopped.
i02790190
Note: Ensure that the engine is either level or that
the engine is in the normal operating position in order Engine Oil Sample - Obtain
to obtain a true level indication.
Note: After the engine has been switched OFF, wait The condition of the engine lubricating oil may be
for ten minutes in order to allow the engine oil to drain checked at regular intervals as part of a preventive
to the oil pan before checking the oil level. maintenance program. Perkins include an oil
sampling valve (1) as an option. The oil sampling
1. Maintain the oil level between the “Low” mark (Y) valve (if equipped) is included in order to regularly
and the “High” mark (X) on the engine oil dipstick. sample the engine lubricating oil.
Do not fill the crankcase above the “High” mark
(X).
72 SEBU8337-03
Maintenance Section
Engine Oil and Filter - Change

To ensure that the sample is representative of the oil

in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
The sample can be checked for the following: the
quality of the oil, the existence of any coolant in the
oil, the existence of any ferrous metal particles in the
oil and the existence of any nonferrous metal
particles in the oil.

i09711083

Engine Oil and Filter - Change

Hot oil and hot components can cause personal

Illustration 38 g01393937
injury. Do not allow hot oil or hot components to
Typical example contact the skin.
Perkins recommends using a sampling valve in order Do not drain the oil when the engine is cold. As the oil
to obtain oil samples. The quality and the consistency cools, suspended waste particles settle on the
of the samples are better when a sampling valve is bottom of the oil pan. The waste particles are not
used. The location of the sampling valve allows oil removed with the draining cold oil. Drain the
that is flowing under pressure to be obtained during crankcase with the engine stopped. Drain the
normal engine operation. crankcase with the oil warm. This draining method
allows the waste particles that are suspended in the
Obtain the Sample and the oil to be drained properly.

Analysis Failure to follow this recommended procedure will

cause the waste particles to be recirculated through
the engine lubrication system with the new oil.

Hot oil and hot components can cause personal

Type 1 Engine Oil Filter
injury. Do not allow hot oil or hot components to
contact the skin. Drain the Engine Oil
In order to help obtain the most accurate analysis, After the engine has been run at the normal
record the following information before an oil sample operating temperature, stop the engine. Use one of
is taken: the following methods to drain the engine crankcase
oil:
• The date of the sample
• If the engine is equipped with a drain valve, turn
• Engine model the drain valve knob counterclockwise to drain the
oil. After the oil has drained, turn the drain valve
• Engine number knob clockwise to close the drain valve.
• Service hours on the engine • If the engine is not equipped with a drain valve,
remove the oil drain plug to allow the oil to drain.
• The number of hours that have accumulated since
Discard the washer. If the engine is equipped with
the last oil change
a shallow sump, remove the bottom oil drain plugs
• The amount of oil that has been added since the from both ends of the oil pan.
last oil change After the oil has drained, the oil drain plug should be
Ensure that the container for the sample is clean and cleaned. Install a new washer to the oil drain plug.
dry. Also ensure that the container for the sample is Reinstall the oil drain plug.
clearly labelled.
SEBU8337-03 73
Maintenance Section
Engine Oil and Filter - Change

Replace the Oil Filter

Illustration 40 g01394084
Typical example

4. Install the filter element into the oil filter housing.

Ensure that the insert (3) on the oil filter aligns to
the square (4) in the oil filter housing.

Illustration 39 g07564055
Typical example

1. Ensure that the oil filter assembly is clean before

the procedure for removing the filter element is
carried out.
2. Use a suitable container to drain the oil filter.
Remove the drain plug (2) and drain the oil. Check
the O ring seal on the drain plug. If necessary,
replace the O ring seal.
3. Remove the oil filter housing (1) and the filter
element from the engine. Discard the old filter
element and the old O ring seal. Clean the oil filter
housing.

Illustration 41 g07564058
Typical example
74 SEBU8337-03
Maintenance Section
Engine Oil and Filter - Change

4. Remove the oil level gauge to check the oil level.

NOTICE
Do not fill the oil filters with oil before installing them. Maintain the oil level between the “Low” and
This oil would not be filtered and could be contami- “High” marks on the oil level gauge.
nated. Contaminated oil can cause accelerated wear
to engine components or engine damage.
Type 2 Engine Oil Filter
5. Install the O ring seal (5). Lubricate the threads on Drain the Engine Oil
the oil filter housing with Special Lubricant
(Perkins part number CV60889). After the engine has been run at the normal
operating temperature, stop the engine. Use the
6. Install the oil filter housing and the element. following method to drain the engine crankcase oil:
Perkins recommends tightening the oil filter
housing (1) up to a torque of 90 N·m (66 lb ft). • Turn the drain valve knob counterclockwise to
drain the oil. After the oil has drained, turn the
Note: Ensure that there is no gap between the drain valve knob clockwise to close the drain
engine oil filter assembly and the engine oil filter valve.
base.
Replace the Oil Filter
7. Install the drain plug (2) and tighten to 1.2 N·m
(11 lb in).

Fill the Engine Crankcase

1. Remove the oil filler cap. Refill the engine
crankcase with engine oil. Refer to the Operation
and Maintenance Manual, “Refill Capacities” and
Operation and Maintenance Manual, “Fluid
recommendations” for more information.

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.

NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.

2. Start the engine and run the engine for 2 minutes.

Perform this procedure to ensure that the
lubrication system has oil and that the oil filters are
filled. Inspect the oil filter for oil leaks.
Illustration 42 g07564062
3. Stop the engine and allow the oil to drain back to Typical example
the sump for a minimum of 10 minutes.
1. Ensure that the oil filter assembly is clean before
the procedure for removing the filter element is
carried out.
2. Use a suitable container to drain the oil filter. Turn
the drain valve (2) knob counterclockwise to drain
the oil. Check the O ring seal on the drain valve. If
necessary, replace the O ring seal.
SEBU8337-03 75
Maintenance Section
Engine Protective Devices - Check

Fill the Engine Crankcase

1. Remove the oil filler cap. Refill the engine
crankcase with engine oil. Refer to the Operation
and Maintenance Manual, “Refill Capacities” and
Operation and Maintenance Manual, “Fluid
recommendations” for more information.

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.

NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.

2. Start the engine and run the engine for 2 minutes.

Perform this procedure to ensure that the
lubrication system has oil and that the oil filters are
filled. Inspect the oil filter for oil leaks.
3. Stop the engine and allow the oil to drain back to
Illustration 43 g07564071 the sump for a minimum of 10 minutes.
Typical example
4. Remove the oil level gauge to check the oil level.
3. Remove the oil filter housing (1) and the oil filter Maintain the oil level between the “Low” and
element (3) from the engine. Discard the old filter “High” marks on the oil level gauge.
element (3) and the old O ring seal (4). Clean the
oil filter housing. i02568161

4. Install the new filter element (3) into the oil filter Engine Protective Devices -
housing (1).
Check
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear Visual Inspection
to engine components or engine damage.
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that are
5. Lubricate the integrated O ring seal (4) with P80 loose, broken, or damaged. Damaged wiring or
Emulsion Rubber Assembly Lubricant. components should be repaired or replaced
immediately.
6. Install the oil filter housing (1) and the oil filter
element (3). Perkins recommends tightening the
oil filter housing (1) up to a torque of 100 N·m
Calibration Check
(74 lb ft).
NOTICE
Note: Ensure that there is no gap between the During testing, abnormal operating conditions must
engine oil filter assembly and the engine oil filter be simulated.
base.
The tests must be performed correctly in order to pre-
vent possible damage to the engine.
7. Turn the drain valve knob (2) clockwise to close
the drain valve.
76 SEBU8337-03
Maintenance Section
Engine Speed/Timing Sensors - Check/Clean/Calibrate

Alarms and shutoffs must function properly. Alarms Refer to the Troubleshooting, “Calibration
provide timely warning to the operator. Shutoffs help Procedures” for more information on the speed/
to prevent damage to the engine. It is impossible to timing sensors.
determine if the engine protective devices are in
good working order during normal operation. i02568163
Malfunctions must be simulated in order to test the
engine protective devices. To prevent damage to the
engine, only authorized service personnel or your Engine Valve Lash - Inspect/
Perkins distributor should perform the tests. Adjust
Consult your Perkins distributor or refer to the
Service Manual for more information.
The initial valve lash adjustment on new engines,
i02790456 rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of the
Engine Speed/Timing Sensors valve train components and to the seating of the
- Check/Clean/Calibrate valve train components.
This maintenance is recommended by Perkins as
part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.

NOTICE
Only qualified service personel should perform this
maintenance. Refer to the Service Manual or your au-
thorized Perkins dealer or your Perkins distributor for
the complete valve lash adjustment procedure.
Operation of Perkins engines with incorrect valve
lash can reduce engine efficiency, and also reduce
engine component life.

Ensure that the engine can not be started while

this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before
measuring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuring

the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance is
performed.
Illustration 44 g01394162
Left side view The following components should be inspected and
adjusted when the valves are inspected and
(1) Secondary position sensor (Camshaft ) adjusted.
(2) Primary position sensor (Crankshaft)
• Valve actuators
1. Remove the sensors from the front housing. Check
the condition of the plastic end of the sensors for • Injectors
wear and/or contaminants.
Refer to Systems Operation, Testing and Adjusting,
2. Clean the metal shavings and other debris from “Engine Valve Lash - Inspect/Adjust” for more
the face of the sensors. Use the procedure in the information.
Service Manual in order to calibrate the speed/
timing sensors.
SEBU8337-03 77
Maintenance Section
Fan Drive Bearing - Lubricate

i02793537

Fan Drive Bearing - Lubricate

Illustration 46 g01394243

3. Loosen the union (2).

Note: Do not remove the union completely. Open the
union enough to allow the air that is trapped to be
Illustration 45 g01395016
purged from the fuel system.
Typical example
4. Unlock the hand priming pump (1). Operate the
Inspect the fan drive pulley assembly for wear or for hand priming pump until fuel free from air flows
damage. If the shaft is loose, an inspection of the
internal components should be performed. Refer to from the union.
the Service Manual for additional information. 5. Tighten the union securely.
Lubricate the grease fitting (1) that is on the fan drive 6. Operate the hand priming pump until a strong
bearing with CV3080 Grease.
pressure is felt on the pump. Push the priming
pump plunger inward and tighten the plunger by
i02790862
hand. Remove the container and clean any split
fuel.
Fuel System - Prime
7. Start the engine.

NOTICE
NOTICE Do not crank the engine continuously for more than
Use a suitable container to catch any fuel that might 30 seconds. Allow the starting motor to cool for 30
spill. Clean up any spilled fuel immediately. seconds before cranking the engine again.

NOTICE 8. If the engine will not start, allow the starting motor
Do not allow dirt to enter the fuel system. Thoroughly to cool for 30 seconds. Repeat steps 3 to 6 in
clean the area around a fuel system component that order to eliminate air from the fuel system.
will be disconnected. Fit a suitable cover over discon-
nected fuel system component. 9. Continue to eliminate air from the fuel system if
these events occur:
1. Turn the ignition switch to the “OFF” position. • The engine starts, but the engine does not run
2. Ensure that the fuel tank is full with clean diesel evenly.
fuel. Place a suitable container under the fuel
• The engine starts, but the engine continues to
filters in order to catch any split fuel.
misfire or smoke.
78 SEBU8337-03
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

10. Run the engine with no load until the engine runs 3. Remove the filter bowl (1) from the assembly.
smoothly. Remove the filter element and the old O ring seal.
Discard both items. Clean the filter bowl.
i02792797

Fuel System Primary Filter

(Water Separator) Element -
Replace

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Illustration 48 g01394544
Typical example

Note: The filter element for the primary fuel filter is

different from the filter element for the secondary fuel
filter. Ensure that the correct filter elements are
installed into the filter system.

4. Ensure that the insert (3) is the same shape as the

tab (2).
5. Align the insert to the tab. Install the element into
the filter bowl.

Illustration 47 g01394516
Typical example

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

position. Place a suitable container under the
primary fuel filter assembly. Clean the outside of
the primary fuel filter assembly.
2. Drain the primary fuel filter. Refer to this Operation
and Maintenance Manual, “Fuel System Primary
Filter/Water Separator - Drain” in order to drain the
primary fuel filter.
SEBU8337-03 79
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

NOTICE
The water separator is not a filter. The water separa-
tor separates water from the fuel. The engine should
never be allowed to run with the water separator
more than half full. Engine damage may result.

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the
fuel system.

Illustration 49 g01394600
Typical example

6. Install the new O ring seal (4). Lubricate the

threads on the bowl assembly with CV60889
Special Lubricant.
7. Install the bowl assembly. Tighten the assembly to
a torque of 80 N·m (59 lb ft).
8. Remove the container and dispose of the fuel
safely. Turn the fuel supply valve (if equipped) to
the ON position.
9. Prime the fuel system. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime” for
more information.
10. Operate the engine and check for fuel leaks.

i02792791 Illustration 50 g01394504

Typical example
Fuel System Primary Filter/
Water Separator - Drain 1. Place a suitable container below the primary fuel
filter assembly (1).
2. Remove the drain plug (2). Allow the fluid to drain
into the container. Check the O ring seal on the
drain plug for damage. If necessary, replace the O
Fuel leaked or spilled onto hot surfaces or electri- ring seal.
cal components can cause a fire. To help prevent
possible injury, turn the start switch off when 3. When clean fuel drains from the primary fuel filter
changing fuel filters or water separator elements. install the drain plug. Tighten the drain plug to the
Clean up fuel spills immediately. following torque 1.2 N·m (11 lb in). Dispose of the
drained fluid correctly.
80 SEBU8337-03
Maintenance Section
Fuel System Secondary Filter - Replace

i02793014 2. Remove the drain plug (1). Allow the fuel to drain
from the filter. Check the O ring seal on the drain
Fuel System Secondary Filter - plug for damage . If necessary, replace the O ring.
Replace 3. Remove the secondary filter bowl (2) from the
assembly. Remove the filter element and the O
ring seal. Discard both items. Clean the filter bowl.

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

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

position. Place a suitable container under the fuel
filter assembly. Clean the outside of the secondary
fuel filter assembly.

Illustration 52 g01394660
Typical example

Note: The filter element for the secondary fuel filter is

different from the element for the primary fuel filter.
Ensure that the correct elements are installed into the
fuel system.

4. Ensure that the insert (4) is the same shape as the

tab (3).
5. Align the insert to the tab and install the element
into the filter bowl.

Illustration 51 g01394652
Typical example
SEBU8337-03 81
Maintenance Section
Fuel Tank Water and Sediment - Drain

Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system.
Water can be introduced into the fuel tank when the
fuel tank is being filled.
Condensation occurs during the heating and cooling
of fuel. The condensation occurs as the fuel passes
through the fuel system and the fuel returns to the
fuel tank. This causes water to accumulate in fuel
tanks. Draining the fuel tank regularly and obtaining
fuel from reliable sources can help to eliminate water
in the fuel.

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
Illustration 53 g01394685
order to drain the water and the sediment. Close the
drain valve.
6. Install a new O ring seal (5). Lubricate the threads
on the bowl assembly with CV60889 Special Check the fuel daily. Allow five minutes after the fuel
tank has been filled before draining water and
Lubricant.
sediment from the fuel tank.
7. Install the bowl assembly. Tighten the bowl
Fill the fuel tank after operating the engine in order to
assembly to a torque of 80 N·m (59 lb ft). Install drive out moist air. This will help prevent
the drain plug and tighten to the following torque condensation. Do not fill the tank to the top. The fuel
1.2 N·m (11 lb in). expands as the fuel gets warm. The tank may
overflow.
8. Turn the valves for the fuel lines (if equipped) to
the ON position. Prime the fuel system. Refer to Some fuel tanks use supply pipes that allow water
the Operation and Maintenance Manual, “Fuel and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
System - Prime” for more information. take fuel directly from the bottom of the tank. If the
9. Remove the split fuel and dispose of the fuel engine is equipped with this system, regular
maintenance of the fuel system filter is important.
safely.
10. Operate the engine and check for fuel leaks. Fuel Storage Tanks
i02568194 Drain the water and the sediment from the fuel
storage tank at the following intervals:
Fuel Tank Water and Sediment • Service intervals
- Drain
• Refill of the tank
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
NOTICE tank.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
82 SEBU8337-03
Maintenance Section
Hoses and Clamps - Inspect/Replace

If a bulk storage tank has been refilled or moved • Type of fitting material
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal • Anticipated expansion and contraction of the hose
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the • Anticipated expansion and contraction of the
storage tank helps to ensure the quality of the fuel. fittings
When possible, water separators should be used.
Replace the Hoses and the Clamps
i02568190

Hoses and Clamps - Inspect/

Replace 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
Inspect all hoses for leaks that are caused by the
pressure cap slowly in order to relieve the
following conditions: pressure.
• Cracking
1. Stop the engine. Allow the engine to cool.
• Softness
2. Loosen the cooling system filler cap slowly in order
• Loose clamps to relieve any pressure. Remove the cooling
Replace hoses that are cracked or soft. Tighten any system filler cap.
loose clamps.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
NOTICE
Do not bend or strike high pressure lines. Do not in-
3. Drain the coolant from the cooling system to a
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and level that is below the hose that is being replaced.
hoses. Leaks can cause fires. Inspect all lines, tubes 4. Remove the hose clamps.
and hoses carefully. Tighten all connections to the
recommended torque. 5. Disconnect the old hose.
6. Replace the old hose with a new hose.
Check for the following conditions:
7. Install the hose clamps.
• End fittings that are damaged or leaking
8. Refill the cooling system.
• Outer covering that is chafed or cut 9. Clean the cooling system filler cap. Inspect the
• Exposed wire that is used for reinforcement cooling system filler cap's gaskets. Replace the
cooling system filler cap if the gaskets are
• Outer covering that is ballooning locally damaged. Install the cooling system filler cap.
• Flexible part of the hose that is kinked or crushed 10. Start the engine. Inspect the cooling system for
leaks.
• Armoring that is embedded in the outer covering
i08257569
A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard Jacket Water Heater - Check
clamp.
Due to extreme temperature changes, the hose will Jacket water heaters help to improve starting in
heat set. Heat setting causes hose clamps to loosen. ambient temperatures that are below 21 °C (70 °F).
This can result in leaks. A constant torque hose All installations that require automatic starting should
clamp will help to prevent loose hose clamps. have jacket water heaters.
Each installation application can be different. The Check the operation of the jacket water heater.
differences depend on the following factors: Check the operation of the circulation pump, if
equipped. For an ambient temperature of 0 °C
• Type of hose (32 °F), the heater should maintain the jacket water
coolant temperature at approximately 32 °C (90 °F).
SEBU8337-03 83
Maintenance Section
Overhaul Considerations

i03039820 Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction of
Overhaul Considerations the fan's air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move
(Top End Overhaul) the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the
tubes.
A scheduled 6000 hour overhaul that is based on Pressurized water may also be used for cleaning.
prime operation of the top end can limit down time of The maximum water pressure for cleaning purposes
the engine. must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
Prime Power both sides.
Use a degreaser and steam for removal of oil and
Operating Parameters grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
70% average load factor that is Limited to a core with clean water.
maximum of 4% of use at rated load (Prime point).
If the radiator is blocked internally, refer to the OEM
for information regarding flushing the cooling system.
i03039981
After cleaning the radiator, start the engine. This will
Overhaul Considerations help in the removal of debris and the drying of the
core. Run the engine for two minutes and then stop
(Major Overhaul) the engine. Inspect the core for cleanliness. Repeat
the cleaning, if necessary.

A scheduled 12000 hour major overhaul can limit i02578376

down time of the engine.
Severe Service Application -
i02857274
Check
Radiator - Clean
Severe service is the application of an engine that
exceeds the current published standards for that
The following text describes a typical cleaning engine. Perkins maintains standards for the following
procedure for the radiator. For information on engine parameters:
equipment that is not supplied by Perkins, refer to the
OEM. • Performance such as power range, speed range,
and fuel consumption
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. • Fuel quality
Inspect the radiator for these items: damaged fins, • Operational Altitude
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary. • Maintenance intervals
• Oil selection and maintenance

Personal injury can result from air pressure. • Coolant type and maintenance

Personal injury can result without following prop- • Environmental qualities

er procedure. When using pressure air, wear a
protective face shield and protective clothing. • Installation

Maximum air pressure at the nozzle must be less • The temperature of the fluid in the engine
than 205 kPa (30 psi) for cleaning purposes.
Refer to the standards for the engine or consult your
Perkins dealer or your Perkins distributor in order to
determine if the engine is operating within the defined
parameters.
84 SEBU8337-03
Maintenance Section
Starting Motor - Inspect

Severe service operation can accelerate component • Failure to use recommended fuel, lubricants and
wear. Engines that operate under severe conditions coolant or antifreeze
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention of i02568202
full service life.
Due to individual applications, it is not possible to Starting Motor - Inspect
identify all of the factors which can contribute to
severe service operation. Consult your Perkins
dealer or your Perkins distributor for the unique Perkins recommends a scheduled inspection of the
maintenance that is necessary for the engine. starting motor. If the starting motor fails, the engine
may not start in an emergency situation.
The operating environment, incorrect operating
procedures and incorrect maintenance procedures Check the starting motor for proper operation. Check
can be factors which contribute to a severe service the electrical connections and clean the electrical
application. connections. Refer to the Service Manual for more
information on the checking procedure and for
Environmental Factors specifications or consult your Perkins distributors for
assistance.
Ambient temperatures – The engine may be
exposed to extended operation in extremely cold i02568203
environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
Turbocharger - Inspect
cold temperatures. Extremely hot intake air reduces
engine performance.
Periodic inspection and cleaning is recommended for
Quality of the air – The engine may be exposed to the turbocharger compressor housing (inlet side).
extended operation in an environment that is dirty or Any fumes from the crankcase are filtered through
dusty, unless the equipment is cleaned regularly. the air inlet system. Therefore, by-products from oil
Mud, dirt and dust can encase components. and from combustion can collect in the turbocharger
Maintenance can be very difficult. The buildup can compressor housing. Over time, this buildup can
contain corrosive chemicals. contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
Buildup – Compounds, elements, corrosive
chemicals and salt can damage some components. If the turbocharger fails during engine operation,
Altitude – Problems can arise when the engine is damage to the turbocharger compressor wheel and/
operated at altitudes that are higher than the or to the engine may occur. Damage to the
intended settings for that application. Necessary turbocharger compressor wheel can cause additional
adjustments should be made. damage to the pistons, the valves, and the cylinder
head.

NOTICE
Incorrect Operating Procedures Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
• Frequent hot shutdowns Loss of engine lubricant can result in serious engine
damage.
• Operating at excessive loads
Minor leakage of a turbocharger housing under ex-
• Operating outside the intended application tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not
Incorrect Maintenance Procedures occurred.
When a turbocharger bearing failure is accompanied
• Extending the maintenance intervals by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.

An inspection of the turbocharger can minimize

unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
SEBU8337-03 85
Maintenance Section
Walk-Around Inspection

Note: Turbocharger components require precision 6. Clean the turbocharger housing with standard
clearances. The turbocharger cartridge must be shop solvents and a soft bristle brush.
balanced due to high rpm. Severe Service
Applications can accelerate component wear. Severe 7. Fasten the air inlet piping and the exhaust outlet
Service Applications require more frequent piping to the turbocharger housing.
inspections of the cartridge.
i02568213
Removal and Installation
Walk-Around Inspection
For options regarding the removal, installation, repair
and replacement, consult your Perkins distributor.
Refer to the Service Manual for this engine for the
procedure and specifications. Inspect the Engine for Leaks and
for Loose Connections
Cleaning and Inspecting
A walk-around inspection should only take a few
1. Remove the exhaust outlet piping and remove the minutes. When the time is taken to perform these
air inlet piping from the turbocharger. Visually checks, costly repairs and accidents can be avoided.
inspect the piping for the presence of oil. Clean the
For maximum engine service life, make a thorough
interior of the pipes in order to prevent dirt from inspection of the engine compartment before starting
entering during reassembly. the engine. Look for items such as oil leaks or
coolant leaks, loose bolts, worn belts, loose
2. Turn the compressor wheel and the turbine wheel connections and trash buildup. Make repairs, as
by hand. The assembly should turn freely. Inspect needed:
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There • The guards must be in the proper place. Repair
should not be any visible signs of contact between damaged guards or replace missing guards.
the turbine wheel or compressor wheel and the • Wipe all caps and plugs before the engine is
turbocharger housing. If there is any indication of serviced in order to reduce the chance of system
contact between the rotating turbine wheel or the contamination.
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned. NOTICE
3. Check the compressor wheel for cleanliness. If For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and
only the blade side of the wheel is dirty, dirt and/or correct the leak. If leaking is suspected, check the flu-
moisture is passing through the air filtering id levels more often than recommended until the leak
system. If oil is found only on the back side of the is found or fixed, or until the suspicion of a leak is
wheel, there is a possibility of a failed turbocharger proved to be unwarranted.
oil seal.
The presence of oil may be the result of extended NOTICE
engine operation at low idle. The presence of oil Accumulated grease and/or oil on an engine or deck
may also be the result of a restriction of the line for is a fire hazard. Remove this debris with steam clean-
ing or high pressure water.
the inlet air (plugged air filters), which causes the
turbocharger to slobber.
• Ensure that the cooling lines are properly clamped
4. Use a dial indicator to check the end clearance on
and that the cooling lines are tight. Check for
the shaft. If the measured end play is greater than leaks. Check the condition of all pipes.
the Service Manual specifications, the
turbocharger should be repaired or replaced. An • Inspect the water pumps for coolant leaks.
end play measurement that is less than the
minimum Service Manual specifications could Note: The water pump seal is lubricated by coolant in
indicate carbon buildup on the turbine wheel. The the cooling system. It is normal for a small amount of
leakage to occur as the engine cools down and the
turbocharger should be disassembled for cleaning
parts contract.
and for inspection if the measured end play is less
than the minimum Service Manual specifications.
5. Inspect the bore of the turbine housing for
corrosion.
86 SEBU8337-03
Maintenance Section
Water Pump - Inspect

Excessive coolant leakage may indicate the need to • Other potential damage to the engine
replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/ Visually inspect the water pump for leaks. If any
or seals, refer to the Service Manual for the engine or leaking is observed, replace the water pump seal or
consult your Perkins distributor. the water pump assembly. Refer to the Service
Manual for the disassembly and assembly
• Inspect the lubrication system for leaks at the front procedure.
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover. Note: Refer to the Service Manual or consult your
Perkins distributor if any repair is needed or any
• Inspect the fuel system for leaks. Look for loose replacement is needed.
fuel line clamps or for loose fuel line tie-wraps.

• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
• Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.

• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection
and for good condition.

• Inspect the ECM to the cylinder head ground strap

for a good connection and for good condition.

• Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
• Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that
can not be calibrated.

i02568235

Water Pump - Inspect

A failed water pump might cause severe engine

overheating problems that could result in the
following conditions:
• Cracks in the cylinder head

• A piston seizure
SEBU8337-03 87
Warranty Section
Warranty Information

Warranty Section

Warranty Information
i06590874

Emissions Warranty
Information

This engine may be certified to comply with exhaust

emission and gaseous emission standards that are
prescribed by the law at the time of manufacture.
This engine may be covered by an Emissions
Warranty. Consult your authorized Perkins dealer or
distributor to determine if your engine is emissions
certified and if your engine is subject to an Emissions
Warranty.
88 SEBU8337-03
Index Section

Index
A D
After Starting Engine ....................................... 35 Diagnostic Lamp.............................................. 33
After Stopping Engine ..................................... 38 Driven Equipment - Check .............................. 66
Aftercooler Core - Clean/Test (Air-To-Air
Aftercooler) .................................................... 58 E
Alternator - Inspect .......................................... 58
Electrical System............................................. 14
Grounding Practice...................................... 15
B
Electronic Unit Injector - Inspect/Adjust .......... 66
Battery - Replace....................................... 58–59 Emissions Certification Film ............................ 22
Battery Electrolyte Level - Check .................... 59 Emissions Warranty Information ..................... 87
Battery or Battery Cable - Disconnect............. 60 Engine - Clean................................................. 67
Before Starting Engine .............................. 13, 34 Engine Air Cleaner Element (Single
Belts - Inspect/Adjust/Replace ........................ 60 Element) - Inspect/Replace ........................... 67
Adjustment of the Fan Drive Belt................. 61 Cleaning the Air Cleaner Element ............... 67
Alternator Belt Adjustment........................... 61 Servicing the Air Cleaner Element .............. 67
Inspection .................................................... 60 Engine Air Cleaner Service Indicator -
Replacement................................................ 61 Inspect (If Equipped) ..................................... 68
Burn Prevention............................................... 10 Engine Crankcase Breather - Replace ........... 69
Batteries........................................................11 Crankcase Breather..................................... 69
Coolant ........................................................ 10 Open Breather ............................................. 70
Oils................................................................11 Engine Description .......................................... 18
Aftermarket Products and Perkins
C Engines ...................................................... 19
Engine Diagnostics ......................................... 33
Cold Weather Operation ................................. 39 Engine Electronics........................................... 15
Hints for Cold Weather Operation ............... 39 Engine Mounts - Inspect.................................. 70
Recommendations for the Coolant.............. 39 Engine Oil and Filter - Change ........................ 72
Viscosity of the Engine Lubrication Oil ........ 39 Type 1 Engine Oil Filter ............................... 72
Cold Weather Starting ..................................... 35 Type 2 Engine Oil Filter ............................... 74
Cooling System Coolant (Commercial Engine Oil Level - Check................................. 71
Heavy-Duty) - Change................................... 62 Engine Oil Sample - Obtain............................. 71
Drain ............................................................ 62 Obtain the Sample and the Analysis ........... 72
Fill ................................................................ 63 Engine Operation ............................................ 37
Flush ............................................................ 62 Engine Operation with Active Diagnostic
Cooling System Coolant (ELC) - Change ....... 63 Codes ............................................................ 33
Drain ............................................................ 64 Engine Operation with Intermittent
Fill ................................................................ 64 Diagnostic Codes .......................................... 33
Flush ............................................................ 64 Engine Protective Devices - Check................. 75
Cooling System Coolant Level - Check........... 65 Calibration Check ........................................ 75
Cooling System Water Temperature Visual Inspection.......................................... 75
Regulator - Replace....................................... 65 Engine Speed/Timing Sensors - Check/
Crankshaft Vibration Damper - Inspect........... 66 Clean/Calibrate.............................................. 76
Visconic Damper.......................................... 66 Engine Starting.......................................... 13, 34
Crushing Prevention and Cutting Prevention.. 13 Engine Stopping ........................................ 14, 38
Customer Specified Parameters ..................... 22 Engine Valve Lash - Inspect/Adjust................. 76
Programmable Monitoring System (PMS)... 22
SEBU8337-03 89
Index Section

F Static Electricity Hazard when Fueling with

Ultra-low Sulfur Diesel Fuel ......................... 9
Fan Drive Bearing - Lubricate ......................... 77
General Information ........................................ 16
Fault Logging................................................... 33
Features and Controls..................................... 28
Fire Prevention and Explosion Prevention.......11 H
Ether ............................................................ 12 Hoses and Clamps - Inspect/Replace............. 82
Fire Extinguisher.......................................... 12 Replace the Hoses and the Clamps ............ 82
Lines, Tubes, and Hoses ............................. 12
Fluid Recommendations ........................... 48, 53
I
Cooling System Specifications .................... 48
ELC Cooling System Maintenance.............. 51 Important Safety Information............................. 2
Engine Oil .................................................... 54
General Lubricant Information..................... 53 J
Fluid Recommendations (Fuel
Specification) ................................................. 42 Jacket Water Heater - Check .......................... 82
Diesel Fuel Characteristics.......................... 44
Diesel Fuel Requirements ........................... 42 L
General Information..................................... 42
Lifting and Storage .......................................... 24
Foreword ........................................................... 4
California Proposition 65 Warning ................. 4
Literature Information .................................... 4 M
Maintenance .................................................. 4 Maintenance Interval Schedule....................... 57
Maintenance Intervals ................................... 5 Daily ............................................................. 57
Operation ....................................................... 4 Every 1000 Service Hours or 1 Year ........... 57
Overhaul ........................................................ 5 Every 12 000 Service Hours or 6 Years....... 57
Safety............................................................. 4 Every 2000 Service Hours........................... 57
Fuel and the Effect from Cold Weather ........... 39 Every 250 Service Hours or 1 Year ............. 57
Fuel Conservation Practices ........................... 37 Every 3000 Service Hours or 2 Years ......... 57
Fuel Related Components in Cold Weather ... 40 Every 500 Service Hours ............................. 57
Fuel Filters ................................................... 40 Every 500 Service Hours or 1 Year ............. 57
Fuel Tanks ................................................... 40 Every 5000 Service Hours........................... 57
Fuel System - Prime ........................................ 77 Every 6000 Service Hours........................... 57
Fuel System Primary Filter (Water Every 6000 Service Hours or 3 Years ......... 57
Separator) Element - Replace....................... 78 Every Week ................................................. 57
Fuel System Primary Filter/Water Initial 500 Service Hours.............................. 57
Separator - Drain ........................................... 79 When Required............................................ 57
Fuel System Secondary Filter - Replace ........ 80 Maintenance Section....................................... 42
Fuel Tank Water and Sediment - Drain ........... 81 Manual Stop Procedure .................................. 38
Drain the Water and the Sediment .............. 81 Emergency Stopping ................................... 38
Fuel Storage Tanks...................................... 81 Stopping the Engine .................................... 38
Fuel Tank ..................................................... 81 Model View Illustrations .................................. 17
Model Views .................................................... 17
G Monitoring System........................................... 28
Action Alert .................................................. 28
Gauges and Indicators .................................... 27
Altitude derate.............................................. 29
General Hazard Information.............................. 7
Critical Protection Override.......................... 28
Containing Fluid Spillage............................... 8
Diagnostic .................................................... 29
Fluid Penetration ........................................... 8
Shutdown..................................................... 28
Inhalation ....................................................... 9
Shutdown Reset .......................................... 29
Pressure Air and Water ................................. 8
Standard Warning Outputs .......................... 29
Warning Alarm ............................................. 28
90 SEBU8337-03
Index Section

Mounting and Dismounting ............................. 13 Starting Motor - Inspect ................................... 84

Starting the Engine.......................................... 34
O New engines ................................................ 34
Starting the Engine ...................................... 34
Operation Section............................................ 24 Starting with Jump Start Cables...................... 35
Overhaul Considerations (Major Overhaul) .... 83
Overhaul Considerations (Top End
T
Overhaul)....................................................... 83
Prime Power ................................................ 83 Table of Contents .............................................. 3
Turbocharger - Inspect .................................... 84
P Cleaning and Inspecting .............................. 85
Removal and Installation ............................. 85
Plate Locations and Film Locations ................ 20
Serial Number Plate (1) ............................... 21
W
Product Identification Information ................... 20
Product Information Section............................ 16 Walk-Around Inspection .................................. 85
Product Lifting ................................................. 24 Inspect the Engine for Leaks and for Loose
Product Storage .............................................. 24 Connections ............................................... 85
Engine.......................................................... 24 Warranty Information....................................... 87
Warranty Section ............................................. 87
R Water Pump - Inspect...................................... 86
Welding on Engines with Electronic
Radiator - Clean .............................................. 83 Controls ......................................................... 16
Reference Numbers ........................................ 21
Record for Reference .................................. 21
Refill Capacities............................................... 42
Cooling System............................................ 42
Lubrication System ...................................... 42

S
Safety Messages............................................... 6
Universal Warning (1) .................................... 6
Safety Section ................................................... 6
Self-Diagnostics .............................................. 33
Sensors and Electrical Components............... 30
Atmospheric Pressure Sensor 4.................. 31
Electronic Control Module 9 ........................ 32
Engine Coolant Temperature Sensor 1 ....... 31
Engine Oil Pressure Sensor 6 ..................... 31
Failure of Sensors........................................ 31
Fuel Temperature Sensor 7 ......................... 32
Intake Manifold Air Temperature Sensor 3 .. 31
Intake Manifold Pressure Sensor 2 ............. 31
Primary Speed/Timing Sensor 8.................. 32
Programmable Monitoring System (PMS)... 31
Secondary Speed/Timing Sensor 5............. 31
Sensor Locations ......................................... 30
Severe Service Application - Check................ 83
Environmental Factors................................. 84
Incorrect Maintenance Procedures ............. 84
Incorrect Operating Procedures .................. 84
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:
SEBU8337
©2023 Perkins Engines Company Limited
All Rights Reserved

92 February 2023