Perkins 2506F-E15TA and 2506J-E15TA Industrial Engine. Operation and Maintenance Manual (2000)

M0076814-03

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

may have caused changes to your engine which are

Diesel engine exhaust and some of its

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

distributor for the latest available information.

and other reproductive harm.

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

Operation

Do not ingest this chemical. Wash hands

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

engine.

compounds, which are known to the

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.

The illustrated, step-by-step instructions are grouped

Literature Information

by service hours and/or calendar time maintenance

intervals. Items in the maintenance schedule are

This manual contains safety, operation instructions,

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.

M0076814-03

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.

M0076814-03

Safety Section

Safety Messages

Safety Section

i06821618

Safety Messages

There may be several specific safety messages on

your engine. The exact location and a description of

the safety messages are reviewed in this section.

Become familiar with all safety messages.

Ensure that all 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 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.

Illustration 1

g06129232

Typical example

(1) Universal warning label

(2) Sulfuric Acid Burn label

M0076814-03

Safety Section

General Hazard Information

This notice should be located next to the battery

• When working around an engine, the engine must

disconnect switch.

not be in operation. You may only be near a

running engine to carry out maintenance

NOTICE

procedures that require the engine to be in

Do not turn the battery power disconnect switch off

operation.

until indicator lamp has turned off. If the switch is

turned off when the light is illuminated then the DEF

• Do not wear loose clothing or jewelry that can

system will not purge and DEF could freeze and

snag on controls or on other parts of the engine.

cause damage to the pump and lines.

• Ensure that all protective guards and all covers

are secured in place on the engine.

i08312804

• Never put maintenance fluids into glass

containers. Glass containers can break.

General Hazard Information

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform the

maintenance under the following conditions:

•

The engine is stopped. Ensure that the engine

cannot be started.

•

The protective locks or the controls are in the

applied position.

•

Engage the secondary brakes or parking brakes.

•

Block the vehicle or restrain the vehicle before

maintenance or repairs are performed.

•

Disconnect the batteries when maintenance is

Illustration 5

g00104545

performed or when the electrical system is

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

serviced. Disconnect the battery ground leads.

warning tag to the start switch or to the controls

Tape the leads to help prevent sparks. If equipped,

before the engine is serviced or before the engine is

allow the diesel exhaust fluid to be purged before

repaired. Attach the warning tags to the engine and

disconnecting the battery.

to each operator control station. When appropriate,

disconnect the starting controls.

•

If equipped, disconnect the connectors for the unit

injectors that are on the valve cover base. This

Do not allow unauthorized personnel on the engine,

action will help prevent personal injury from the

or around the engine when the engine is being

high voltage to the unit injectors. Do not come in

serviced.

contact with the unit injector terminals while the

engine is operating.

• Tampering with the engine installation or

tampering with the OEM supplied wiring can be

•

Do not attempt any repairs or any adjustments to

dangerous. Personal injury, death and/or engine

the engine while the engine is operating.

damage could result.

•

Do not attempt any repairs that are not

• Vent the engine exhaust to the outside when the

understood. Use the proper tools. Replace any

engine is operated in an enclosed area.

equipment that is damaged or repair the

equipment.

• If the engine is not running, do not release the

secondary brake or the parking brake systems

•

For initial start-up of a new engine or for starting

unless the vehicle is blocked or unless the vehicle

an engine that has been serviced, make

is restrained.

provisions to stop the engine if an overspeed

occurs. The stopping of the engine may be

• Wear a hard hat, protective glasses, and other

accomplished by shutting off the fuel supply and/

protective equipment, as required.

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.

M0076814-03

Safety Section

General Hazard Information

• Start the engine from the operators station (cab).

• Never put maintenance fluids into glass

Never short across the starting motor terminals or

containers. Glass containers can break.

the batteries. This action could bypass the engine

neutral start system and/or the electrical system

• Use all cleaning solutions with care.

could be damaged.

• Report all necessary repairs.

Engine exhaust contains products of combustion

Unless other instructions are provided, perform

which may be harmful to your health. Always start the

the maintenance under the following conditions:

engine and operate the engine in a well ventilated

area. If the engine is in an enclosed area, vent the

• The engine is stopped. Ensure that the engine

engine exhaust to the outside.

cannot be started.

Cautiously remove the following parts. To help

• Disconnect the batteries when maintenance is

prevent spraying or splashing of pressurized fluids,

hold a rag over the part that is being removed.

performed or when the electrical system is

serviced. Disconnect the battery ground leads.

• Filler caps

Tape the leads to help prevent sparks.

• Grease fittings

• Do not attempt any repairs that are not

understood. Use the proper tools. Replace any

• Pressure taps

equipment that is damaged or repair the

equipment.

• Breathers

• Drain plugs

Pressurized Air and Water

Use caution when cover plates are removed.

Pressurized air and/or water can cause debris and/or

Gradually loosen, but do not remove the last two

hot water to be blown out. This action could result in

personal injury.

bolts or nuts that are at opposite ends of the cover

plate or the device. Before removing the last two

When pressurized air and/or pressurized water is

bolts or nuts, pry the cover loose to relieve any spring

used for cleaning, wear protective clothing, protective

pressure or other pressure.

shoes, and eye protection. Eye protection includes

goggles or a protective face shield.

The maximum air pressure for cleaning purposes

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

water pressure for cleaning purposes must be below

275 kPa (40 psi).

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long

after the engine has been stopped. The pressure can

cause hydraulic fluid or items such as pipe plugs to

escape rapidly if the pressure is not relieved

correctly.

Do not remove any hydraulic components or parts

Illustration 6

g00702020

until pressure has been relieved or personal injury

may occur. Do not disassemble any hydraulic

• Wear a hard hat, protective glasses, and other

components or parts until pressure has been relieved

protective equipment, as required.

or personal injury may occur. Refer to the OEM

information for any procedures that are required to

• Perkins recommend that you do not stand next to

relieve the hydraulic pressure.

an exposed running engine unless it is necessary

when carrying out daily checks or maintenance

procedures. The appropriate Personal Protective

Equipment (PPE) must be worn when standing

next to an exposed running engine.

• Do not wear loose clothing or jewelry that can

snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers

are secured in place on the engine.

M0076814-03

Safety Section

General Hazard Information

Avoid static electricity risk when fueling. Ultra-

low sulfur diesel fuel (ULSD fuel) poses a greater

static ignition hazard than earlier diesel formula-

tions with a higher sulfur contents. Avoid death

or serious injury from fire or explosion. Consult

with your fuel or fuel system supplier to ensure

the delivery system is in compliance with fueling

standards for proper grounding and bonding

practices.

Inhalation

Illustration 7

g00687600

Always use a board or cardboard when you check for

a leak. Leaking fluid that is under pressure can

penetrate body tissue. Fluid penetration can cause

serious injury and possible death. A pin hole leak can

cause severe injury. If fluid is injected into your skin,

you must get treatment immediately. Seek treatment

from a doctor that is familiar with this type of injury.

Containing Fluid Spillage

Care must be taken to ensure that fluids are

contained during performance of inspection,

maintenance, testing, adjusting, and repair of the

product. Be prepared to collect the fluid with suitable

containers before opening any compartment or

Illustration 8

g00702022

disassembling any component containing fluids.

Exhaust

Dispose of all fluids according to local regulations

and mandates.

Use caution. Exhaust fumes can be hazardous to

health. If you operate the equipment in an enclosed

Static Electricity Hazard when

area, adequate ventilation is necessary.

Fueling with Ultra-low Sulfur Diesel

Hexavalent Chromium

Fuel

Perkins equipment and replacement parts comply

The removal of sulfur and other compounds in ultra-

with applicable regulations and requirements where

low sulfur diesel fuel (ULSD fuel) decreases the

originally sold. Perkins recommends the use of only

conductivity of ULSD and increases the ability of

genuine Perkins replacement parts.

ULSD to store static charge. Refineries may have

treated the fuel with a static dissipating additive.

Hexavalent chromium has occasionally been

detected on exhaust and heat shield systems on

Many factors can reduce the effectiveness of the

Perkins engines. Although laboratory testing is the

additive over time. Static charges can build up in

only accurate way to know if hexavalent chromium is,

ULSD fuel while the fuel is flowing through fuel

in fact, present, the presence of a yellow deposit in

delivery systems. Static electricity discharge when

areas of high heat (for example, exhaust system

combustible vapors are present could result in a fire

components or exhaust insulation) may be an

or explosion. Ensure that the entire system used to

indication of the presence of hexavalent chromium.

refuel your machine (fuel supply tank, transfer pump,

transfer hose, nozzle, and others) is properly

Use caution if you suspect the presence of

grounded and bonded. Consult with your fuel or fuel

hexavalent chromium. Avoid skin contact when

system supplier to ensure that the delivery system

handling items that you suspect may contain

complies with fueling standards for proper grounding

hexavalent chromium, and avoid inhalation of any

and bonding.

dust in the suspect area. Inhalation of, or skin contact

with, hexavalent chromium dust may be hazardous to

your health.

M0076814-03

Safety Section

General Hazard Information

If such yellow deposits are found on the engine,

• Use exhaust ventilation on permanent machining

engine component parts, or associated equipment or

jobs.

packages, Perkins recommends following local

health and safety regulations and guidelines, utilizing

• Wear an approved respirator if there is no other

good hygiene, and adhering to safe work practices

way to control the dust.

when handling the equipment or parts. Perkins also

recommends the following:

• Comply with applicable rules and regulations for

the work place. In the United States, use

• Wear appropriate Personal Protective Equipment

Occupational Safety and Health Administration

(PPE)

(OSHA) requirements. These OSHA requirements

can be found in “29 CFR 1910.1001”.

• Wash your hands and face with soap and water

prior to eating, drinking, or smoking, and also

• Obey environmental regulations for the disposal of

during rest room breaks, to prevent ingestion of

asbestos.

any yellow powder

• Stay away from areas that might have asbestos

• Never use compressed air for cleaning areas

particles in the air.

suspected of containing hexavalent chromium

Dispose of Waste Properly

• 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

genuine Perkins replacement parts. Use the following

guidelines when you handle any replacement parts

that contain asbestos or when you handle asbestos

Illustration 9

g00706404

debris.

Improperly disposing of waste can threaten the

Use caution. Avoid inhaling dust that might be

environment. Potentially harmful fluids should be

generated when you handle components that contain

disposed of according to local regulations.

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.

• Use a wet method to clean up asbestos materials.

• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be

used.

M0076814-03

Safety Section

Burn Prevention

Always use leakproof containers when you drain

Cooling system conditioner contains alkali. Alkali can

fluids. Do not pour waste onto the ground, down a

cause personal injury. Do not allow alkali to contact

drain, or into any source of water.

the skin, the eyes, or the mouth.

Diesel Exhaust Fluid

Oils

Skin may be irritated following repeated or prolonged

exposure to mineral and synthetic base oils. Refer to

your suppliers Material Safety Data Sheets for

DEF is an aqueous solution of urea which can re-

detailed information. Hot oil and lubricating

lease ammonia vapors. Always wear the appro-

components can cause personal injury. Do not allow

priate Personal Protective Equipment (PPE) that

hot oil to contact the skin. Appropriate personal

is noted on a material safety data sheet (MSDS)

protective equipment should be used.

for Diesel Exhaust Fluid (DEF).

• Do not inhale ammonia vapor or mist

Diesel Fuel

• Do not eat, drink, or smoke in presence of DEF

Diesel may be irritating to the eyes, respiratory

system, and skin. Prolonged exposure to diesel may

• Avoid DEF contact with eyes, skin, and

cause various skin conditions. Appropriate personal

protective equipment should be used. Refer to

clothing

supplier Material safety Data sheets for detailed

• Wash thoroughly after handling DEF

information.

Always follow the directions for first aid that are

Batteries

noted on a material safety data sheet (MSDS) for

Diesel Exhaust Fluid (DEF).

The liquid in a battery is an electrolyte. Electrolyte is

an acid that can cause personal injury. Do not allow

DEF is not expected to produce significant adverse

electrolyte to contact the skin or the eyes.

health effects when the recommended instructions

for use are followed.

Do not smoke while checking the battery electrolyte

levels. Batteries give off flammable fumes which can

• Draining DEF must be carried out in a well

explode.

ventilated area.

Always wear protective glasses when you work with

• Do not allow the DEF to be spilled onto hot

batteries. Wash hands after touching batteries. The

surfaces.

use of gloves is recommended.

i06086863

Engine and Aftertreatment System

Burn Prevention

Do not touch any part of an operating engine or

engine aftertreatment system. Allow the engine or the

engine aftertreatment system to cool before any

maintenance is performed on the engine or the

Coolant

engine aftertreatment system. Relieve all pressure in

the appropriate system before any lines, fittings, or

When the engine is at operating temperature, the

related items are disconnected.

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 in

order to relieve pressure.

M0076814-03

Safety Section

Fire Prevention and Explosion Prevention

Aftertreatment System and Diesel

Store fuels and lubricants in correctly marked

containers away from unauthorized persons. Store

Exhaust Fluid

oily rags and any flammable materials in protective

containers. Do not smoke in areas that are used for

Diesel Exhaust Fluid (DEF) temperatures can reach

storing flammable materials.

65° to 70°C (149.° to 126°F) during normal engine

operation. Stop the engine. Wait for 15 minutes in

Do not expose the engine to any flame.

order to allow the DEF system to be purged and the

DEF to cool before service or repair is performed.

Exhaust shields (if equipped) protect hot exhaust

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

i05945996

tube, or a seal failure. Exhaust shields must be

installed correctly.

Fire Prevention and Explosion

Do not weld on lines or tanks that contain flammable

Prevention

fluids. Do not flame cut lines or tanks that contain

flammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior to

welding or flame cutting.

Wiring must be kept in good condition. 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.

Illustration 10

g00704000

Ensure that the engine is stopped. Inspect all lines

All fuels, most lubricants, and some coolant mixtures

and hoses for wear or for deterioration. Ensure that

are flammable.

the hoses are correctly routed. The lines and hoses

must have adequate support and secure clamps.

Flammable fluids that are leaking or spilled onto hot

surfaces or onto electrical components can cause a

Oil filters and fuel filters must be installed correctly.

fire. Fire may cause personal injury and property

The filter housings must be tightened to the correct

damage.

torque. Refer to the Disassembly and Assembly

manual for more information.

After the emergency stop button is operated, ensure

that you allow 15 minutes, before the engine covers

are removed.

Determine whether the engine will be operated in an

environment that allows combustible gases to be

drawn into the air inlet system. These gases could

cause the engine to overspeed. Personal injury,

property damage, or engine damage could result.

If the application involves the presence of

combustible gases, consult your Perkins dealer and/

or your Perkins distributor for additional information

about suitable protection devices.

Remove all flammable combustible materials or

conductive materials such as fuel, oil, and debris

from the engine. Do not allow any flammable

combustible materials or conductive materials to

accumulate on the engine.

M0076814-03

Safety Section

Fire Prevention and Explosion Prevention

Illustration 11

g00704059

Illustration 12

g00704135

Use caution when you are refueling an engine. Do

Gases from a battery can explode. Keep any open

not smoke while you are refueling an engine. Do not

flames or sparks away from the top of a battery. Do

refuel an engine near open flames or sparks. Always

not smoke in battery charging areas.

stop the engine before refueling.

Never check the battery charge by placing a metal

Avoid static electricity risk when fueling. Ultra-low

object across the terminal posts. Use a voltmeter or a

Sulfur Diesel fuel (ULSD fuel) poses a greater static

hydrometer.

ignition hazard than earlier diesel formulations with a

higher sulfur content. Avoid death or serious injury

Incorrect jumper cable connections can cause an

from fire or explosion. Consult your fuel or fuel

explosion that can result in injury. Refer to the

system supplier to ensure that the delivery system is

Operation Section of this manual for specific

in compliance with fueling standards for proper

instructions.

grounding and bonding practices.

Do not charge a frozen battery. A frozen battery 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

Ether is flammable and poisonous.

Do not smoke while you are replacing an ether

cylinder or while you are using an ether spray.

M0076814-03

Safety Section

Crushing Prevention and Cutting Prevention

Do not store ether cylinders in living areas or in the

i05768982

engine compartment. Do not store ether cylinders in

direct sunlight or in temperatures above 49° C

Mounting and Dismounting

(120° F). Keep ether cylinders away from open

flames or sparks.

Do not climb on the engine or the engine

Lines, Tubes, and Hoses

aftertreatment system. The engine and

aftertreatment system have not been designed with

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

mounting or dismounting locations.

pressure lines. Do not install any lines that are

damaged.

Refer to the OEM for the location of foot and hand

holds for your specific application.

Leaks can cause fires. Consult your Perkins dealer or

your Perkins distributor for replacement parts.

i04257031

Replace the parts if any of the following conditions

are present:

Before Starting Engine

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

NOTICE

For initial start-up of a new or rebuilt engine, and for

• Wires are exposed.

start-up of an engine that has been serviced, make

provision to shut the engine off should an overspeed

• Outer coverings are ballooning.

occur. This may be accomplished by shutting off the

air and/or fuel supply to the engine.

• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Engine exhaust contains products of combustion

Make sure that all clamps, guards, and heat shields

which may be harmful to your health. Always

are installed correctly. During engine operation,

start and operate the engine in a well ventilated

correct installation will help to prevent vibration,

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

rubbing against other parts, and excessive heat.

to the outside.

Inspect the engine for potential hazards.

i02143194

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

Crushing Prevention and

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

warning tag attached to the start switch or to the

Cutting Prevention

controls.

Before starting the engine, ensure that no one is on,

underneath, or close to the engine. Ensure that the

Support the component correctly when work beneath

the component is performed.

area is free of personnel.

Unless other maintenance instructions are provided,

If equipped, ensure that the lighting system for the

never attempt adjustments while the engine is

engine is suitable for the conditions. Ensure that all

running.

lights work properly, if equipped.

Stay clear of all rotating parts and of all moving parts.

All protective guards and all protective covers must

Leave the guards in place until maintenance is

be installed if the engine must be started in order to

performed. After the maintenance is performed,

perform service procedures. To help prevent an

reinstall the guards.

accident that is caused by parts in rotation, work

around the parts carefully.

Keep objects away from moving fan blades. The fan

blades will throw objects or cut objects.

Do not start an engine when the governor linkage is

disconnected.

When objects are struck, wear protective glasses in

Do not bypass the automatic shutoff circuits. Do not

order to avoid injury to the eyes.

disable the automatic shutoff circuits. The circuits are

provided in order to help prevent personal injury. The

Chips or other debris may fly off objects when objects

circuits are also provided in order to help prevent

are struck. Before objects are struck, ensure that no

engine damage.

one will be injured by flying debris.

M0076814-03

Safety Section

Engine Starting

i07828827

i06822945

Engine Starting

Engine Stopping

Do not stop the engine immediately after the engine

has been operated under load. Abrupt stopping of the

engine can cause overheating and accelerated wear

Do not use aerosol types of starting aids such as

of engine components. Allow the engine to run for 5

ether. Such use could result in an explosion and

minutes before engine shutdown. Running the

personal injury.

engine allows hot areas of the engine to cool

gradually.

i06088340

Engine exhaust contains products of combustion

Electrical System

which may be harmful to your health. Always

start and operate the engine in a well ventilated

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

to the outside.

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit

If a warning tag is attached to the engine start switch

is operating. A spark can cause the combustible

or to the controls, DO NOT start the engine or move

gases that are produced by some batteries to ignite.

the controls. Consult with the person that attached

the warning tag before the engine is started.

To help prevent sparks from igniting combustible

gases that are produced by some batteries, the

All protective guards and all protective covers must

negative “-” jump-start cable should be connected

be installed if the engine must be started to perform

last from the external power source to the negative

service procedures. To help prevent an accident that

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

is caused by parts in rotation, work around the parts

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

carefully.

the jump-start cable to the engine block.

Start the engine from the operator's compartment or

Check the electrical wires daily for wires that are

from the engine start switch.

loose or frayed. Tighten all loose electrical wires

before the engine is started. Repair all frayed

Always start the engine according to the procedure

electrical wires before the engine is started. Refer to

that is described in the Operation and Maintenance

the “Engine Starting” section of this Operation and

Manual, “Engine Starting” topic in the Operation

Maintenance Manual for specific starting instructions.

Section. Knowing the correct procedure will help to

prevent major damage to the engine components.

Grounding Practices

Knowing the procedure will also help to prevent

personal injury.

Proper grounding for the engine electrical system is

To ensure that the jacket water heater (if equipped) is

necessary for optimum engine performance and

working correctly, check the water temperature

reliability. Improper grounding will result in

gauge and/or the oil temperature gauge during the

uncontrolled electrical circuit paths and in unreliable

heater operation.

electrical circuit paths.

Note: The engine may be equipped with a device for

Uncontrolled electrical circuit paths can result in

cold starting. If the engine will be operated in very

damage to main bearings, to crankshaft bearing

cold conditions, then an extra cold starting aid may

journal surfaces, and to aluminum components.

be required. Normally, the engine will be equipped

Engines that are installed without engine-to-frame

with the correct type of starting aid for your region of

ground straps can be damaged by electrical

operation.

discharge.

To ensure that the engine and the engine electrical

systems function properly, an engine-to-frame

ground strap with a direct path to the battery must be

used. This path may be provided by way of a starting

motor ground, a starting motor ground to the frame,

or a direct engine ground to the frame.

M0076814-03

Safety Section

Engine Electronics

All grounds should be tight and free of corrosion. The

engine alternator must be grounded to the negative

“-” battery terminal with a wire that is adequate to

handle the full charging current of the alternator.

i06091234

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) will 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

monitoring control: WARNING, DERATE and

SHUTDOWN. These engine monitoring modes can

limit engine speed and/or the engine power.

Many of the parameters that are monitored by the

ECM can be programmed for the engine monitoring

functions. The following parameters can be

monitored as a part of the Engine Monitoring System:

• Operating Altitude

• Engine Coolant Level

• Engine Coolant Temperature

• Engine Oil Pressure

• Engine Speed

• Fuel Temperature

• Intake Manifold Air Temperature

• System Voltage

The Engine Monitoring package can vary for different

engine models and different engine applications.

However, the monitoring system and the engine

monitoring control will be similar for all engines.

Note: Many of the engine control systems and

display modules that are available for Perkins

Engines will work in unison with the Engine

Monitoring System. Together, the two controls will

provide the engine monitoring function for the specific

engine application. Refer to the Troubleshooting

Manual for more information.

M0076814-03

Product Information Section

Product Description

Pump Electronic Tank Unit (PETU)

NOx Sensors and DEF Heated line

Illustration 16

g06129412

Illustration 17

g06044238

Typical example

(1) DEF filler cap

(1) NOx sensors

(2) DEF tank

(2) DEF heated line

(3) DEF tank header

(4) DEF pump filter

i06823092

(5) DEF tank drain

Product Description

The Perkins 2506F-E15TA Industrial Engine has the

following characteristics:

• Four-stroke cycle

• Mechanically actuated, electronically controlled

fuel injection system

• Turbocharged

• Air to air charged cooled

• Aftertreatment system

The Clean Emissions Module (CEM) is constructed

of four main items, the diesel Aftertreatment

Regeneration Device (ARD) oxidation catalyst, the

diesel particulate filter, and the Selective Catalytic

Reduction (SCR). The SCR requires the use of

Diesel Exhaust Fluid (DEF) to be injected into the

system to lower the emissions from the engine. The

(DEF) is stored and controlled by the pump electronic

tank unit. The DEF tank can be installed separate

from the electronic pump unit.

M0076814-03

Product Information Section

Product Description

Engine Specifications

• Torque rise shaping

Note: The front end of the engine is opposite the

• Injection timing control

flywheel end of the engine. The left and the right

• System diagnostics

sides of the engine are determined from the flywheel

end. The number 1 cylinder is the front cylinder.

• Aftertreatment regeneration control

• NOX reduction system control

Extra Features

The following extra features provide increased

engine fuel economy and serviceability:

• Cold starting capability

• Tampering detection

• Diagnostics

Engine Diagnostics

Illustration 18

g01387009

The engine has built-in diagnostics to ensure that all

Cylinder and valve location

the components are functioning properly. Under

certain conditions, the engine horsepower and the

(A) Exhaust valve

vehicle speed may be limited. An electronic service

(B) Inlet valve

tool may be used to display the diagnostic code.

Table 1

There are two categories of codes: diagnostic code

Engine Specifications

and event code. These two categories of codes may

be in two different states: active and logged.

Engine

2506F-E15TA

Most of the diagnostic codes are logged and stored in

Arrangement and Cylinders

In-Line 6 cylinder

the ECM. For additional information, refer to

Bore

137 mm (5.4 inch)

theOperation and Maintenance Manual, Engine

Diagnostictopic (Operation Section).

Stroke

171 mm (6.7 inch)

Aspiration

ATAAC⁽¹⁾

Engine Service Life

Displacement

15.2 L (927 cubic inch)

Engine efficiency and maximum utilization of engine

performance depend on the adherence to proper

Firing Order

1-5-3-6-2-4

operation and maintenance recommendations. In

Rotation (flywheel end)

Counterclockwise

addition, use recommended fuels, coolants, and

lubricants. Use the Operation and Maintenance

⁽¹⁾ Air-to-air aftercooled

Manual as a guide for required engine maintenance.

Expected engine life is predicted by the average

Electronic Engine Features

power that is demanded. The average power that is

demanded is based on fuel consumption of the

The engine is designed for electronic controls. The

engine over a time. Reduced hours of operation at

integral on board computer controls the operation of

full throttle and/or operating at reduced throttle

the engine. Current operating conditions are

settings result in a lower average power demand.

monitored. The Electronic Control Module (ECM)

Reduced hours of operation will increase the length

controls the response of the engine to these

of operating time before an engine overhaul is

conditions and to the demands of the operator. These

required. For more information, refer to the Operation

conditions and operator demands determine the

and Maintenance Manual, “Overhaul Considerations”

precise control of fuel injection by the ECM. The

topic.

electronic engine control system provides the

following features:

Aftermarket Products and Perkins

• Engine speed governor

Engines

• Automatic air/fuel ratio control

Perkins does not warrant the quality or performance

of non-Perkins fluids and filters.

M0076814-03

Product Information Section

Emissions Certification Film

Illustration 21

g06040627

Illustration 23

g06040642

(3) CEM Identification plate

Typical example

(4) PETU Plate location

Illustration 22

g02236574

CEM identification plate

Illustration 24

g03049116

Typical example PETU serial plate

The CEM identification plate contains the following

information: part number, serial number, change

Record the information on the CEM and PETU serial

level, and configuration ID code. This information

plates. The information will be required by your

may be needed by the Perkins distributor when

Perkins distributor to identify replacement part

inquiries are being made on the CEM.

numbers.

Pump Electronic Tank Unit (PETU)

i05951816

and Pump Electronic Unit (PEU)

Emissions Certification Film

Note: Some applications may not have a diesel

exhaust fluid tank installed into to the electronic unit.

Note: This information is pertinent in the United

States, in Canada and in Europe.

The emissions label is located on the top of the valve

mechanism cover.

M0076814-03

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i07433042

Product Lifting

Illustration 25

g00103219

NOTICE

Always inspect lifting eyebolts and all other lifting

equipment for damage before performing any lifting.

Never bend the eyebolts and the brackets. Never

perform product lifting if components are damaged.

Only load the eyebolts and the brackets under ten-

sion. Remember that the capacity of an eyebolt is

less as the angle between the supporting members

and the object becomes less than 90 degrees.

Use a hoist to remove heavy components. Use an

adjustable lifting beam to lift the engine. All

supporting members (chains and cables) should be

parallel to each other. The chains and cables should

be perpendicular to the top of the object that is being

lifted.

Some removals require lifting the fixtures to obtain

proper balance and safety.

To remove the engine ONLY, use the lifting eyes that

are on the engine.

Lifting eyes are designed and installed for the

specific engine arrangement. Alterations to the lifting

eyes and/or the engine make the lifting eyes and the

lifting fixtures obsolete. If alterations are made,

ensure that proper lifting devices are provided.

Consult your Perkins distributor for information

regarding fixtures for proper engine lifting.

M0076814-03

Operation Section

Product Storage

Remove any ATAAC lines, air cleaners, or other

Ensure that all 4 lifting eyes are used when lifting the

attachments that would otherwise interfere with the

CEM. Only use the lifting eyes (1) and lifting eyes (2)

lift chains or other lifting devises. The engine

for lifting the CEM, refer to illustration 27 .

package center of gravity will change depending on

the engine attachments. Adjust the spreader bar and

Pump Electronic Tank Unit (PETU)

chains as necessary to maintain a lift within 5

degrees of horizontal in all directions.

Radiator Only

Detach the radiator, and mounting bracket at the

engine front support. Add eyebolts or lifting brackets

to the threaded holes marked for lifting.

Clean Emission Module (CEM)

Lifting

Illustration 28

g06129926

Typical example

(1 PETU lifting eyes

i06605082

Product Storage

(Engine and Aftertreatment)

Your Perkins distributor can help in preparing the

engine for extended storage periods.

Some applications, the engine can be equipped with

delayed engine shutdown. Allow at least 2 minutes

after the engine has stopped before you turn the

battery disconnect switch to OFF. Disconnecting the

Illustration 27

g06042325

battery power too soon will prevent purging of the

Typical example

DEF fluid lines after the engine is shut down. Also,

during the 2 minutes the engine electronic control

(1) CEM lifting eyes

module is active storing information from the engine

(2) CEM lifting eyes

and aftertreatment sensors.

Condition for Storage

An engine can be stored for up to 6 months provided

all the recommendation are adhered to.

M0076814-03

Operation Section

Engine and Aftertreatment

Engine

Open the fuel tank drain valve to drain any water

and dirt from the fuel tank. Apply a spray of

1. Clean the engine of any dirt, rust, grease, and oil.

calibration fluid or kerosene at the rate of

Inspect the exterior. Paint areas that contain paint

30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank

damage with a good quality paint.

capacity to prevent rust in the fuel tank. Add

0.15 mL per L (.02 oz per 1 gal US) of commercial

2. Remove dirt from the air cleaners. Check all seals,

biocide such as Biobor JF to the fuel.

gaskets, and the filter element for damage.

Apply a small amount of oil to the threads on the

3. Apply lubricant to all points in this Operation and

fuel tank filler neck and install the cap. Seal all

Maintenance Manual, “Maintenance Interval

openings to the tank to prevent evaporation of the

Schedule”.

fuel and as a preservative.

4. Drain the crankcase oil. Replace the crankcase oil

9. Remove the fuel injectors. Apply 30 mL (1 oz) of

and change the oil filters. For the proper

the mixture of oils (50 percent VCI oil and 50

procedure, refer to this Operation and

percent engine oil) into each cylinder.

Maintenance Manual.

Use a bar or a turning tool to turn over the engine

5. Add Volatile Corrosion Inhibitor (VCI) oil to the

slowly. This procedure puts the oil on the cylinder

crankcase oil. The volume of VCI oil in the

walls. Install all fuel injectors and tighten to the

crankcase oil should be 3 to 4 percent.

correct torque. Refer to Disassembly and

Note: If the engine crankcase is full, drain enough

Assembly Manual for more information.

engine oil so the mixture can be added.

10. Spray a thin amount of a mixture of 50 percent

VCI oil and 50 percent engine oil onto the following

6. Remove the air filter elements. Turn the engine at

components: flywheel, ring gear teeth, and starter

cranking speed with the throttle control in FUEL

pinion. Install the covers to prevent evaporation of

OFF position. Use a sprayer to add a mixture of 50

the vapors from the VCI oil.

percent VCI oil and 50 percent engine oil into the

air inlet or turbocharger inlet.

11. Apply a heavy amount of Multipurpose Grease to

all outside parts that move, such as rod threads,

Note: The mixture of VCI oil can be added to the inlet

ball joints, linkage.

by removing the plug for checking turbocharger boost

pressure. The minimum application rate for the VCI

Note: Install all covers. Ensure that tape has been

oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of

installed over all openings, air inlets, exhaust

engine displacement.

openings, the flywheel housing, the crankcase

breathers, the dipstick tubes.

7. Use a sprayer to apply a mixture of 50 percent VCI

oil and 50 percent crankcase oil into the exhaust

Ensure that all covers are airtight and

openings. The minimum application rate for the oil

weatherproof. Use a waterproof weather resistant

mixture is 5.5 mL per L (3 oz per 1000 cu in) of

tape such as Kendall No. 231 or an equivalent. Do

engine displacement. Seal the exhaust pipe and

not use duct tape. Duct tape will only seal for a

seal any drain holes in the muffler.

short time.

8. Remove the fuel from the secondary fuel filter

12. Under most conditions, removing the batteries is

housing. Alternately, empty and reinstall the spin-

the best procedure. As an alternative, place the

on fuel filter element to remove any dirt and water.

batteries in storage. As needed, periodically

Drain any sleeve metering fuel pump.

charge the batteries whilst the batteries are in

Clean the primary fuel filter. Fill with calibration

storage.

fluid or kerosene. Install the primary fuel filter and

If the batteries are not removed, wash the tops of

operate the priming pump. This procedure will

the batteries until the tops are clean. Apply an

send clean oil to the secondary filter and the

electrical charge to the batteries to obtain a

engine.

specific gravity of 1.225.

Disconnect the battery terminals. Place a plastic

cover over the batteries.

13. Remove the drive belts from the engine

M0076814-03

Operation Section

Engine and Aftertreatment

14. Place a waterproof cover over the engine. Ensure

6. Use a bar or a turning tool to turn the engine in the

that the engine cover is secure. The cover should

normal direction of rotation. The procedure

be loose enough to allow air to circulate around

ensures that no hydraulic locks or resistance exist.

the engine to prevent damage from condensation.

7. Before starting the engine, remove the valve cover

15. Attach a tag with the storage date to the engine.

or covers. Put a large amount of engine oil on the

camshaft, cam followers, and valve mechanism to

16. Remove the waterproof cover at 2 month or 3-

prevent damage to the mechanism.

month intervals to check the engine for corrosion.

If the engine has signs of corrosion, repeat the

protection procedure.

Coolant System

Completely fill the cooling system before storage.

Refer to this Operation and Maintenance Manual,

“Fluid Recommendations” for more information about

coolants.

Aftertreatment

The engine must be allowed to perform a Diesel

Exhaust Fluid (DEF) purge before the battery

disconnect switch is turned off. Some applications,

the engine can be equipped with delayed engine

shutdown. Allow 2 minutes after the engine has

stopped before disconnecting the battery disconnect

switch.

The exhaust outlet of the aftertreatment must be

capped. To prevent damage to the exhaust outlet

connection during storage, the weight of the CEM

must not act on the exhaust outlet.

1. Ensure normal engine shutdown, allow the DEF to

be purged. Do not disconnect the battery

disconnect switch, allow 2 minutes after key off

before disconnection.

Illustration 29

g06042459

2. Fill the tank with DEF that meets all the

Typical example

requirement defined in ISO 22241-1.

(1) Plug

3. Ensure that all DEF lines and electrical connection

are connected prior to prevent crystal from

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

forming.

recommends Pre lubrication of the engine to avoid

dry starting. Use a suitable pump to put engine oil

4. Ensure that the DEF filler cap is correctly installed.

into the engine oil system.

Remove Engine from Storage

The pump will need to create a minimum pressure

within the engine of 0.25 bar (3.6 psi). This

1. Remove all outside protective covers.

pressure is needed for 15 seconds to lubricate the

internal surfaces.

2. Change the oil and filters.

3. Check the condition of the fan and alternator belts.

Replace the belts, if necessary. Refer to this

Operation and Maintenance Manual, “Belts -

Inspect/Adjust/Replace” for the correct procedure.

4. Replace the fuel filter elements.

5. Remove the plastic covers from the air cleaner

elements.

M0076814-03

Operation Section

Engine and Aftertreatment

Remove one of the plugs shown in illustration 29

4. If the fault continues to stay active, refer to

to connect to the engine oil system. The

Troubleshooting for more information.

connection required is 9/16" x 18 tpi. Ensure that

Table 2

the correct oil specification is used, refer to this

DEF Storage

Operation and Maintenance Manual, “Fluid

Recommendations” for more information. After the

Temperature

Duration

engine internal surfaces have been lubricated,

10° C (50° F)

36 months

remove connector and install plug (1). Tighten plug

25° C (77° F)

18 months

to a torque of 30 N·m (265 lb in). Perkins

recommends that the procedure must be

30° C (86° F)

12 months

performed in a minimum ambient temperature of

35° C (95° F)⁽¹⁾

6 months

10° C (50° F).

⁽¹⁾ At 35° C, significant degradation can occur. Check every batch

9. Check the condition of all rubber hoses. Replace

before use.

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.

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.

Remove Aftertreatment from Storage

DEF has a limited life, refer to table 2 for the time and

temperature range. DEF that is outside this range

MUST be replaced.

On removal from storage the DEF quality in the tank

must be tested with a refractometer. The DEF in the

tank must meet the requirements defined in ISO

22241-1 and comply with table 2 .

1. If necessary, drain the tank and fill with DEF that

meets ISO 22241-1.

2. Replace the DEF filter, refer to this Operation, and

Maintenance Manual, “Diesel Exhaust Fluid Filter-

Clean/Replace”.

3. Ensure that the drive belt is correctly installed.

Ensure that all engine coolant and engine oil has

the correct specification and grade. Ensure that

the coolant and the engine oil are at the correct

level. Start the engine. If a fault becomes active

turn off the engine, allow 2 minutes for the DEF

system to purge, then restart the engine.

M0076814-03

Operation Section

Features and Controls

Note: Some items have been removed from engine

Features and Controls

for clarity.

i06163203

Monitoring System

The monitoring system is designed to alert the

operator to an immediate problem with any of the

engine systems that are monitored. The monitoring

system is also designed to alert the operator to an

impending problem with any of the engine systems

that are monitored. The monitoring system can be

accessed by the electronic service tool. For more

information on the electronic service tool, refer to

Troubleshooting , “Electronic Tools”.

Monitoring System Indicators

Engine Malfunction - This indicator

illuminates when there is a fault with the

engine or after treatment system.

Engine STOP - This indicator will

illuminate solid when a level 3 warning

fault has been detected by the

monitoring system.

Diesel Particulate Filter (DPF) - This

indicator will illuminate in order to show

that a regeneration is needed.

Regeneration Active - This indicator will

illuminate in order to show that a

regeneration is active and exhaust

temperatures are elevated.

Diesel Exhaust Fluid (DEF) Level - This

gauge shows the amount of DEF in the

DEF tank.

Emission Malfunction Indicator - This

indicator will illuminate when an

emissions system related to DEF or SCR

has failed. Refer to Operation and Maintenance

Manual, “Selective Catalytic Reduction Warning

System” for more information.

i06825072

Sensors and Electrical

Components

The illustrations within the following sections are

typical location of the sensors or electrical

components for an industrial engine. Specific

engines may appear different due to differences in

applications.

M0076814-03

Operation Section

Battery Disconnect Switch

DEF header (1) contains level sensor temperature

The battery disconnect switch and the engine start

sensor and quality sensor.

switch perform different functions. The entire

electrical system is disabled when you turn the

battery disconnect switch to the OFF position. The

i05422613

battery remains connected to the electrical system

when you turn the engine start switch to the OFF

Battery Disconnect Switch

position.

(If Equipped)

Turn the battery disconnect switch to the OFF

position and remove the key when you service the

electrical system or any other engine components.

Turn the battery disconnect switch to the OFF

position and remove the disconnect switch key after

you operate the engine. This will prevent the battery

from being discharged. The following problems can

cause battery discharge:

• short circuits

• current draw via some components

• vandalism

i07507902

Selective Catalytic Reduction

Illustration 35

g03422039

Warning System

NOTICE

Do not turn off the battery disconnect switch until the

The selective catalytic reduction (SCR system is a

indicator lamp has turned off. If the switch is turned

system used to reduce NOx emissions from the

off when the indicator lamp is illuminated the Diesel

engine. Diesel exhaust fluid (DEF is pumped from

Exhaust Fluid (DEF) system will not purge the DEF. If

the DEF tank and is sprayed into the exhaust stream.

the DEF does not purge, DEF could freeze and dam-

The DEF reacts with the SCR catalyst to reduce NOx

age the pump and lines.

and leaves a nitrogen and water vapor. The Exhaust

Gas Recirculation (EGR system cools, measures,

and introduces recalculated exhaust gas into the

NOTICE

intake manifold to aid in NOx reduction.

Never move the battery disconnect switch to the OFF

position while the engine is operating. Serious dam-

The engine and emissions control system shall be

age to the electrical system could result.

operated, used, and maintained in accordance with

the instructions provided to the end user to maintain

the emissions performance of the engine within the

Battery Disconnect Switch - The battery

requirements applicable to the category of the

disconnect switch can be used in order

engine. No deliberate tampering with, or misuse of

to disconnect the battery from the

the engine emissions control system should take

engines electrical system. The key must be

place. In particular regarding deactivating, or not

inserted into the battery disconnect switch

maintaining the SCR system.

before the battery disconnect switch can be

turned.

NOTICE

Stopping the engine immediately after the engine has

ON - To activate the electrical system,

been working under load can result in overheating of

insert the disconnect switch key and

SCR components.

turn the battery disconnect switch

Refer to the Operation and Maintenance Manual,

clockwise. The battery disconnect switch must

“Engine Stopping” procedure to allow the engine to

be turned to the ON position before you start the

cool and to prevent excessive temperatures in the

engine.

turbocharger housing and the DEF injector.

OFF - To deactivate the electrical

system, turn the battery disconnect

switch counterclockwise to the OFF

position.

M0076814-03

Operation Section

Selective Catalytic Reduction Warning System

Safe Harbor Mode (European Union) - Safe

NOTICE

Harbor Mode is a 30 minute engine run time period

Allow at least 2 minutes after shutting down the en-

that the engine can be operated with full power after

gine before you turn the battery disconnect switch to

reaching a level 3 inducement. Once in level 3

OFF. Disconnecting the battery power too soon will

inducement, the operator can perform a key cycle

prevent purging of the DEF lines after the engine is

and the engine will enter Safe Harbor Mode. Safe

shut down.

Harbor Mode can only be implemented up to three

times.

Definitions

NOTICE

Observe the following definitions.

It is essential to take prompt action to rectify any in-

correct operation, use, or maintenance of the emis-

Self-correct - Fault condition no longer exists. An

sions SCR control system in accordance with the

active fault code will no longer be active.

rectification measures indicated by the warnings

listed on the following pages.

Notification - Action taken by the system to alert the

operator of pending Inducement.

Inducement - Engine derates, vehicle speed limits,

or other actions intended to prompt the operator to

repair or maintain the emission control system.

Inducement Categories - The Inducements are

separated into categories. DEF Level has its own

inducement fault codes and is separate from the

other inducement categories. Whilst DEF level

inducements are simplybased on the DEF level, the

other inducement categories are based on escalating

time. The escalating time inducements will always

have an associated fault code along with the

inducement fault code. The associated fault is the

root cause. The escalating time inducement fault

code is just an indicator of what level of inducement

the engine is in and how much time remains until the

next level of inducement. There are three inducement

Illustration 36

g03676102

categories (two for European Union) that will trigger

DEF Level Normal

an escalating time inducement fault code.

Inducement Strategy for DEF Level

Note: The associated codes for each of the

(European Union)

escalating time categories can be found in the

Troubleshooting Guide under SCR Warning System

Problem.

First occurrence - When an escalating time

inducement fault code becomes active for the first

time.

Repeat occurrence - When any escalating time

inducement fault code becomes active again within

40 hours of the first occurrence. Engine must run for

40 hours without tripping any escalating time

inducement fault before it can get back on first

occurrence times.

Safe Harbor Mode (Worldwide) - Safe Harbor

Mode is a 20 minute engine run time period that the

engine can be operated with full power after reaching

a level 3 inducement. Once in level 3 inducement, the

Illustration 37

g03676107

operator can perform a key cycle and the engine will

enter Safe Harbor Mode. Safe Harbor Mode can only

If the DEF level falls below 20%, an amber indicator

be implemented once. Safe Harbor Mode is not

will illuminate next to the DEF level gauge on the

allowed for DEF level inducements with Worldwide

dash. To avoid further inducements, turn the key to

configuration.

the OFF position and add DEF to the DEF tank.

M0076814-03

Operation Section

Selective Catalytic Reduction Warning System

Illustration 38

g03676111

Illustration 40

g03676127

If the DEF level falls below 13.5%, a level 1

Reduced Time

inducement event will occur. The check engine lamp

and the emissions malfunction indicator lamp will

If the ECM is configured to “Reduced Time” and the

illuminate. The amber indicator next to the DEF level

DEF level is 0%, the engine will be in level 3

gauge on the dash will remain lit.

inducement. The check engine lamp and emissions

malfunction indicator lamp will illuminate and flash at

a fast rate. A red stop lamp will illuminate solid. The

DEF level gauge amber lamp will remain lit. The

engine will have a 100% derate and be limited to

1000 rpm or low idle, whichever is greater. If the final

inducement action in ET is set to “Idle Down” , then

the engine will continue to idle at derated condition. If

set to “Shutdown” , engine will shut down after 5

minutes. Safe Harbor Mode is allowed for three key

cycles. After Safe Harbor Mode is completed, the

engine will return to idle or shut down. If in shutdown

configuration, the engine may be restarted, but will

only run for 5 minutes at derated condition before

shutting down again. This action will continue until

the issue is resolved.

Illustration 39

g03676123

Note: Turn the key to the OFF position and add DEF

to the DEF tank to reset the DEF level inducement.

Reduced Performance

Inducement Strategy for Escalating

When the ECM is configured to "Reduced

Performance" and the DEF level is below 1%, the

Time Inducement Faults (European

engine will be in level 2 inducement. The check

engine lamp and emissions malfunction indicator

Union)

lamp will illuminate and flash slowly. The DEF level

gauge amber lamp will remain lit. The engine will

have a 50% derate. When the DEF tank has been

emptied of all DEF, the engine will have a 100%

derate and be limited to 1000 rpm or low idle,

whichever is greater. No further inducement action

will occur for "Reduced Performance" configuration.

Safe Harbor Mode is allowed for three key cycles.

Reduced Time

Illustration 41

g03677836

When the ECM is configured to “Reduced Time” and

the DEF level is below 7.5%, the engine will be in

Reduced Performance

level 2 inducement. The check engine lamp and

emissions malfunction indicator lamp will illuminate

and flash slowly. The DEF level gauge amber lamp

will remain lit.

M0076814-03

Operation Section

Selective Catalytic Reduction Warning System

The check engine and emissions malfunction

If the inducement is a result of a category 2 fault, then

indicator lamp will illuminate for a level 1 inducement-

a level 2 inducement will occur for a duration of 5

related fault. There are two inducement categories. If

hours. For repeat occurrence, a category 2 level 2

the inducement is a result of a category 1 fault, then a

inducement fault will occur for a duration of 1 hour.

level 1 inducement will occur for a duration of 36

hours. If the inducement is a result of a category 2

fault, then a level 1 inducement will occur for a

duration of 10 hours. There is no repeat occurrence

for level 1 faults.

Reduced Time

The check engine and emissions malfunction

indicator lamp will illuminate for a level 1 inducement-

Illustration 43

g03676141

related fault. There are two inducement categories. If

the inducement is a result of a category 1 fault, then a

Reduced Time

level 1 inducement will occur for a duration of 18

hours. If the inducement is a result of a category 2

If configured to “Reduced Time” and a fault condition

fault, then a level 1 inducement will occur for a

exists for the entire duration of inducement level 2,

duration of 5 hours. There is no repeat occurrence for

the strategy advances to inducement level 3.

level 1 faults.

Inducement level 3 has the same actions for all

categories. The check engine lamp and emissions

malfunction indicator lamp will flash at a fast rate. A

red stop lamp will also illuminate solid. The engine

will have a 100% derate and be limited to 1000 rpm

or low idle, whichever is greater. If the final

inducement action in ET is set to “Idle Down” , then

engine will continue to idle at derated condition. If set

to “Shutdown” , engine will shut down after 5 minutes.

A key cycle will allow safe harbor mode to initiate.

Illustration 42

g03676138

Safe harbor is allowed up to three times. After safe

harbor, the engine will be in level 3 final inducement.

Reduced Performance

If set to “Shutdown” , the engine may be restarted,

but will only run for 5 minutes at derated condition

If a fault condition exists for the entire duration of

before shutting down again. This action will continue

inducement level 1, the strategy advances to

until the issue is resolved.

inducement level 2. The check engine lamp and the

emissions malfunction indicator lamp will illuminate

Note: Contact your Perkins dealer for repairs if a fault

and flash slowly. If the inducement is a result of a

occurs.

category 1 fault, then a level 2 inducement will occur

for a duration of 64 hours for first occurrence. For

repeat occurrence, a category 1 level 2 inducement

Inducement Strategy for DEF Level

fault will occur for a duration of 5 hours.

(Worldwide)

If the inducement is a result of a category 2 fault, then

a level 2 inducement will occur for a duration of 10

hours. For repeat occurrence, a category 2 level 2

inducement fault will occur for a duration of 2 hours.

The engine will have a 50% derate. If the fault is not

corrected before the inducement duration ends, the

engine will become 100% derated and be limited to

1000 rpm or low idle, whichever is greater. No further

inducements will occur for “Reduced Performance”

configuration. Safe Harbor Mode is allowed for three

key cycles.

Reduced Time

If a fault condition exists for the entire duration of

inducement level 1, the strategy advances to

inducement level 2. The check engine lamp and the

emissions malfunction indicator lamp will illuminate

Illustration 44

g03676164

and flash slowly. If the inducement is a result of a

category 1 fault, then a level 2 inducement will occur

If the DEF level falls below 20%, an amber indicator

for a duration of 18 hours for first occurrence. For

will illuminate next to the DEF level gauge on the

repeat occurrence, a category 1 level 2 inducement

dash. To avoid inducements, turn the key to the OFF

fault will occur for a duration of 108 minutes.

position and add DEF to the DEF tank.

M0076814-03

Operation Section

Selective Catalytic Reduction Warning System

Illustration 45

g03676169

Illustration 47

g03676210

If the DEF level falls below 13.5%, a level 1

If the ECM is configured to “Reduced Performance”

inducement event will occur. The check engine lamp

and the DEF tank has been emptied of all DEF, the

and the emissions malfunction indicator lamp will

engine will be in a level 3 final inducement. If the

illuminate. The amber indicator next to the DEF level

ECM is configured to “Reduced Time” and the DEF

gauge on the dash will remain lit.

level is 3%, the engine will be in a level 3 final

inducement. The check engine lamp and the

emissions malfunction indicator lamp will flash at a

fast rate and a red stop lamp will illuminate solid. The

engine will be taken too low idle or will be shut down.

Once shut down, the engine can be restarted for 5

minute periods at reduced speed and torque. If set to

idle, the engine will idle indefinitely at reduced torque.

The amber indicator next to the DEF level gauge on

the dash will remain lit.

Note: Turn the key to the OFF position and add DEF

to the DEF tank to reset the DEF level inducement.

Inducement Strategy for Escalating

Time Inducement Faults

Illustration 46

g03676174

(Worldwide)

If the DEF level is below 7.5%, a level 2 inducement

event will occur. The check engine lamp and the

emissions malfunction indicator lamp will illuminate

and flash slowly. The amber indicator next to the DEF

level gauge on the dash will remain lit. If the ECM is

configured to “Reduced Performance” and the DEF

level has reached 1%, the machine will be limited to

75% torque.

Illustration 48

g03676215

Reduced Performance

The check engine and emissions malfunction

indicator lamp will illuminate for a level 1 inducement-

related fault. There are three inducement categories.

If the inducement is a result of a category 1 fault, then

a level 1 inducement will occur for a duration of 2.5

hours for first occurrence. For repeat occurrence, a

category 1 level 1 inducement fault will occur for a

duration of 5 minutes.

M0076814-03

Operation Section

Selective Catalytic Reduction Warning System

If the inducement is a result of a category 2 fault, then

The check engine and emissions malfunction

a level 1 inducement will occur for a duration of 10

indicator lamp will illuminate for an inducement-

hours. There is no repeat occurrence for category 2,

related fault. There are three inducement categories.

level 1 inducement faults.

If the inducement is a result of a category 1 fault, then

a level 1 inducement will occur for a duration of 2.5

If the inducement is a result of a category 3 fault, then

hours for first occurrence. For repeat occurrence, a

a level 1 inducement will occur for a duration of 36

category 1 level 1 inducement fault will occur for a

hours. There is no repeat occurrence for category 3,

duration of 5 minutes.

level 1 inducement faults.

If the inducement is a result of a category 2 fault, then

Reduced Time The check engine and emissions

a level 1 inducement will occur for a duration of 5

malfunction indicator lamp will illuminate for a level 1

hours. There is no repeat occurrence for category 2,

inducement-related fault. There are three inducement

level 1 inducement faults.

categories. If the inducement is a result of a category

1 fault, then a level 1 inducement will occur for a

If the inducement is a result of a category 3 fault, then

duration of 2.5 hours for first occurrence. For repeat

a level 1 inducement will occur for a duration of 18

occurrence, a category 1 level 1 inducement fault will

hours. There is no repeat occurrence for category 3,

occur for a duration of 5 minutes.

level 1 inducement faults.

If the inducement is a result of a category 2 fault, then

a level 1 inducement will occur for a duration of 5

hours. There is no repeat occurrence for category 2,

level 1 inducement faults.

If the inducement is a result of a category 3 fault, then

a level 1 inducement will occur for a duration of 18

hours. There is no repeat occurrence for category 3,

level 1 inducement faults.

Illustration 50

g03676218

If a fault condition exists for the entire duration of

inducement level 2, the strategy advances to

inducement level 3. Inducement level 3 has the same

actions for all categories. The check engine lamp and

the emissions malfunction indicator lamp will flash at

a fast rate. A red stop lamp will illuminate solid. The

engine will have a 100% derate and be limited to

1000 rpm or low idle, whichever is greater. If the final

Illustration 49

g03676215

inducement action in ET is set to "Idle Down", then

engine will continue to idle at derated condition. If set

Reduced Performance If a fault condition exists for

to "Shutdown" , engine will shut down after 5

the entire duration of inducement level 1, the strategy

minutes. A key cycle will allow safe harbor mode to

advances to inducement level 2. The check engine

initiate. Safe harbor is only allowed once. After safe

and emissions malfunction indicator lamp will

harbor, the engine will be in level 3 final inducement.

illuminate and flash slowly for a level 2 inducement-

If set to "Shutdown", the engine may be restarted, but

related fault. The engine will have a 50% derate. If

will only run for 5 minutes at derated condition before

the inducement is a result of a category 1 fault, then a

shutting down again. This action will continue until

level 2 inducement will occur for a duration of 70

minutes for first occurrence. For repeat occurrence, a

the issue is resolved.

category 1 level 2 inducement fault will occur for a

Note: Contact your Perkins dealer for repairs if a fault

duration of 5 minutes.

occurs.

If the inducement is a result of a category 2 fault, then

a level 2 inducement will occur for a duration of 10

hours. For repeat occurrence, a category 2 level 2

inducement fault will occur for a duration of 2 hours.

If the inducement is a result of a category 3 fault, then

a level 2 inducement will occur for a duration of 64

hours. For repeat occurrence, a category 3 level 2

inducement fault will occur for a duration of 5 hours.

Reduced Time

M0076814-03

Operation Section

Engine Diagnostics

i05194988

Self-Diagnostics

Perkins Electronic Engines have the capability to

perform a self-diagnostics test. When the system

detects an active problem, a diagnostic lamp is

activated. Diagnostic codes will be stored in

permanent memory in the Electronic Control Module

(ECM. The diagnostic codes can be retrieved by

using Perkins electronic service tools.

Some installations have electronic displays that

provide direct readouts of the engine diagnostic

codes. Refer to the manual that is provided by the

OEM for more information on retrieving engine

diagnostic codes.

Active codes represent problems that currently exist.

These problems should be investigated first.

Logged codes represent the following items:

• Intermittent problems

• Recorded events

• Performance history

The problems may have been repaired since the

logging of the code. These codes do not indicate that

a repair is needed. The codes are guides or signals

when a situation exists. Codes may be helpful to

troubleshoot problems.

When the problems have been corrected, the

corresponding logged fault codes should be cleared.

i05406659

Fault Logging

The system provides the capability of Fault Logging.

When the Electronic Control Module (ECM

generates an active diagnostic code, the code will be

logged in the memory of the ECM. The codes that

have been logged by the ECM can be identified by

the electronic service tool. The active codes that

have been logged will be cleared when the fault has

been rectified or the fault is no longer active. The

following logged faults cannot be cleared from the

memory of the ECM without using a factory

password: Overspeed, low engine oil pressure, high

engine coolant temperature, and aftertreatment

codes.

M0076814-03

Operation Section

Engine Starting

•

Do not start the engine or move any of the controls

Engine Starting

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

similar warning tag attached to the start switch or

i02109067

to the controls.

Before Starting Engine

•

Ensure that the areas around the rotating parts are

clear.

•

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

Perform the required daily maintenance and other

damaged guards or for missing guards. Repair

periodic maintenance before the engine is started.

any damaged guards. Replace damaged guards

Inspect the engine compartment. This inspection can

and/or missing guards.

help prevent major repairs at a later date. Refer to

the Operation and Maintenance Manual,

•

Disconnect any battery chargers that are not

“Maintenance Interval Schedule” for more

protected against the high current drain that is

information.

created when the electric starting motor (if

• For the maximum service life of the engine, make

equipped) is engaged. Check electrical cables and

a thorough inspection before the engine is started.

check the battery for poor connections and for

Look for the following items: oil leaks, coolant

corrosion.

leaks, loose bolts and trash buildup. Remove trash

•

Reset all of the shutoffs or alarm components.

buildup and arrange for repairs, as needed.

•

Check the engine lubrication oil level. Maintain the

• Inspect the aftercooler for loose connections and

oil level between the “ADD” mark and the “FULL”

for debris buildup.

mark on the oil level gauge.

• Inspect the cooling system hoses for cracks and

•

Check the coolant level. Observe the coolant level

for loose clamps.

in the coolant recovery tank (if equipped). Maintain

• Inspect the alternator and accessory drive belts for

the coolant level to the “FULL” mark on the coolant

cracks, breaks, and other damage.

recovery tank.

• Inspect the wiring for loose connections and for

•

If the engine is not equipped with a coolant

worn wires or frayed wires.

recovery tank maintain the coolant level within

13 mm (0.5 inch) of the bottom of the filler pipe. If

• Check the fuel supply. Drain water from the water

the engine is equipped with a sight glass, maintain

separator (if equipped). Open the fuel supply

the coolant level in the sight glass.

valve.

•

Observe the air cleaner service indicator (if

equipped). Service the air cleaner when the yellow

NOTICE

diaphragm enters the red zone, or when the red

All valves in the fuel return line must be open before

and during engine operation to help prevent high fuel

piston locks in the visible position.

pressure. High fuel pressure may cause filter housing

•

Ensure that any driven equipment has been

failure or other damage.

disengaged. Minimize electrical loads or remove

any electrical loads.

If the engine has not been started for several weeks,

fuel may have drained from the fuel system. Air may

i06092648

have entered the filter housing. Also, when fuel filters

have been changed, some air pockets will be trapped

Starting the Engine

in the engine. In these instances, prime the fuel

system. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” for more information

on priming the fuel system.

Engine exhaust contains products of combustion

which may be harmful to your health. Always

Engine exhaust contains products of combustion

start and operate the engine in a well ventilated

which may be harmful to your health. Always

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

start and operate the engine in a well ventilated

to the outside.

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

to the outside.

M0076814-03

Operation Section

Starting the Engine

Note: Oil pressures and fuel pressures should be in

the normal range on the instrument panel. Engines

Refer to the Owners Manual of the OEM for your type

that are equipped with “WARNING” lamps do not

of controls. Use the following procedure to start the

have an operating range. The “WARNING and

engine.

DIAGNOSTIC” lamp (if equipped) will flash while the

engine is cranking. The lamp should turn off after

1. Place the transmission in NEUTRAL. Disengage

proper engine oil pressure or fuel pressure is

the flywheel clutch in order to allow the engine to

achieved. Do not apply a load to the engine or

start faster, and to reduce the draining of the

increase engine rpm until the oil pressure gauge

battery.

indicates at least normal pressure. Inspect the engine

for leaks and/or unusual noises.

2. Turn the ignition switch to the ON position.

If the engine is operated with a low load, the engine

During the key on, all warning lamps will illuminate

will reach normal operating temperature sooner than

for a few seconds, in order to test the circuits. If

idling the engine with no load. When the engine is

any lamps do not illuminate, check the bulbs and

idled in cold weather, increase the engine rpm to

replace as necessary.

approximately 1000 to 1200 rpm in order to raise

engine temperature. Do not exceed the

NOTICE

recommended rpm in order to increase the speed of

Do not engage the starting motor when flywheel is

the warm-up. Limit unnecessary idle time to 10

turning. Do not start the engine under load.

minutes.

If the engine fails to start within 30 seconds, release

Starting Problems

the starter switch or button and wait two minutes to

allow the starting motor to cool before attempting to

An occasional starting problem may be caused by

start the engine again.

one of the following items:

3. Push the start button or turn the ignition switch to

• Low battery charge

the START position in order to crank the engine.

• Lack of fuel

Do not push down or hold the throttle down while

• Problem with the wiring harness

the engine is cranked. The system will

automatically provide the correct amount of fuel

If the engine fuel system has been run dry, fill the fuel

that is needed to start the engine.

tank and prime the fuel system. Refer to the

Operation and Maintenance Manual, “Fuel System -

4. If the engine fails to start within 30 seconds,

Prime” topic (Maintenance Section).

release the start button, or the ignition switch. Wait

for 2 minutes in order to allow the starting motor to

cool before attempting to start the engine again.

NOTICE

Oil pressure should rise within 15 seconds after the

engine starts. Do not increase engine rpm until the oil

pressure gauge indicates normal. If oil pressure is

not indicated on the gauge within 15 seconds, DO

NOT operate the engine. STOP the engine, investi-

gate and correct the cause.

5. Allow the engine to idle for approximately 3

minutes. Idle the engine until the water

temperature gauge has begun to rise. Check all

gauges during the warm-up period.

M0076814-03

Operation Section

Cold Weather Starting

If the other problems are suspected, perform the

Note: If the engine has not been run for several

appropriate procedure in order to start the engine.

weeks, fuel may have drained. Air may have moved

into the filter housing. Also, when fuel filters have

Problems with the Wiring Harness

been changed, some air will be left in the filter

housing. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” (Maintenance

Section) for more information on priming the fuel

system.

Ether Injection System (If

Equipped)

The ether injection system is controlled by the ECM.

The ECM monitors the coolant temperature, intake

air temperature, ambient air temperature, and

barometric pressure to determine when ether

injection is needed. At sea level, ether will be used if

any of the temperatures fails to exceed 0° C (32° F).

This temperature is subject to an increase as

barometric pressure increases.

Personal injury or property damage can result

from alcohol or starting fluids.

Alcohol or starting fluids are highly flammable

Illustration 51

g01248812

and toxic and if improperly stored could result in

ECM Connector J2/P2

injury or property damage.

Locate the ECM. Check the connector in order to

ensure that the connector is secure. Lightly pull each

Follow the procedure in this Operation and

of the wires in the chassis harness.

Maintenance Manual, “Starting the Engine”.

1. Pull each wire with approximately 4.5 kg (10 lb) of

i08134367

force. The wire should remain in the connector.

2. If a wire is loose, push the wire back into the

Starting with Jump Start

connector. Pull the wire again in order to ensure

Cables

that the wire is secure.

(Do Not Use This Procedure in

3. Start the engine. If the engine does not start, check

for a diagnostic code and consult your Perkins

Hazardous Locations that have

distributor.

Explosive Atmospheres)

i04132731

Cold Weather Starting

The connection of battery cables to a battery and

Startability will be improved at temperatures below

the disconnection of battery cables from a battery

10°C (50°F from the use of a cylinder block coolant

may cause an explosion which may result in in-

heater or from other means that are used to heat the

jury or death. The connection and the disconnec-

crankcase oil. Some engine applications use a jacket

tion of other electrical equipment may also cause

water heater to improve startability. Use of a jacket

an explosion which may result in injury or death.

water heater will help reduce white smoke and

The procedures for the connection and the dis-

misfire during start-up in cold weather.

connection of battery cables and other electrical

equipment should only be performed in a nonex-

plosive atmosphere.

M0076814-03

Operation Section

After Starting Engine

3. Connect one negative end of the jump-start cable

to the negative cable terminal of the electrical

Improper jump start cable connections can cause

source. Connect the other negative end of the

an explosion resulting in personal injury.

jump-start cable to the engine block or to the

chassis ground. This procedure helps to prevent

Prevent sparks near the batteries. Sparks could

potential sparks from igniting the combustible

cause vapors to explode. Do not allow jump start

gases that are produced by some batteries.

cable ends to contact each other or the engine.

Note: The engine ECM must be powered before the

starting motor is operated or damage can occur.

Note: If possible, first diagnose the reason for the

starting failure. Refer to Troubleshooting, “Engine

4. Start the engine in the normal operating

Will Not Crank and Engine Cranks But Will Not Start”

procedure. Refer to this Operation and

for further information. Make any necessary repairs.

Maintenance Manual, “Starting the Engine”.

If the engine will not start only due to the condition of

the battery, either charge the battery, or start the

5. Immediately after the engine is started, disconnect

engine by using another battery with jump-start

the jump-start cables in reverse order.

cables. The condition of the battery can be

rechecked after the engine has been switched OFF.

After jump starting, the alternator may not be able to

recharge fully batteries that are severely discharged.

The batteries must be replaced or charged to the

NOTICE

Never attempt to start an engine from an external

proper voltage with a battery charger after the engine

power source such as electric welding equipment,

is stopped. Many batteries which are considered

which has a voltage that is unsuitable for engine

unusable are still rechargeable. Refer to Operation

starting and will damage the electrical system.

and Maintenance Manual, “Battery - Replace” and

Testing and Adjusting Manual, “Battery - Test”.

For 904D-E28T industrial engines, use a 12 VDC bat-

tery source to start the engine.

i05359363

For 904D-E36TA industrial engines, ensure that a 12

VDC or 24 VDC battery source is used to start the

After Starting Engine

engine.

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

NOTICE

the warm-up time is approximately 3 minutes. In

Using a battery source with the same voltage as the

temperatures below 0°C (32°F, additional warm-up

electric starting motor. Use ONLY equal voltage for

time may be required.

jump starting. The use of higher voltage will damage

the electrical system.

When the engine is idling during warm-up, observe

the following conditions:

Do not reverse the battery cables. The alternator can

be damaged. Attach ground cable last and remove

• Check for fluid or air leaks at idle rpm and at one-

first.

half full rpm (no load on the engine) before

Turn all electrical accessories OFF before attaching

operating the engine under load. Operating the

the jump start cables.

engine at idle and at one-half full rpm with no load

is not possible in some applications.

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

tion before attaching the jump start cables to the en-

• Operate the engine at low idle until all systems

gine being started.

achieve operating temperatures. Check all gauges

during the warm-up period.

1. Turn the start switch on the stalled engine to the

Note: Gauge readings should be observed and the

OFF position. Turn off all the engines accessories.

data should be recorded frequently while the engine

is operating. Comparing the data over time will help

2. Connect one positive end of the jump-start cable to

to determine normal readings for each gauge.

the positive cable terminal of the discharged

Comparing data over time will also help detect

battery. Connect the other positive end of the

abnormal operating developments. Significant

jump-start cable to the positive cable terminal of

changes in the readings should be investigated.

the electrical source.

M0076814-03

Operation Section

Engine Operation

This design of DPF will require a service

Engine Operation

maintenance interval. Refer to this Operation and

Maintenance Manual, “Maintenance Interval

i06603162

Schedule” for more information. The DPF can be

expected to function properly for the useful life of the

engine (emissions durability period), as defined by

Engine Operation

regulation, subject to prescribed maintenance

requirements being followed.

Proper operation and maintenance are key factors in

i07512817

obtaining the maximum life and economy of the

engine. If the directions in the Operation and

Diesel Particulate Filter

Maintenance Manual are followed, costs can be

minimized and engine service life can be maximized.

Regeneration

The time that is needed for the engine to reach

normal operating temperature can be less than the

time taken for a walk-around inspection.

Regeneration

The engine can be operated at the rated rpm after

the engine is started and after the engine reaches

Regeneration is to increase the exhaust temperature

operating temperature. The engine will reach normal

for a given time. The Aftertreatment Regeneration

operating temperature sooner during a low engine

Device (ARD creates the heat which makes

speed (rpm and during a low-power demand. This

regeneration possible. The regeneration process is

procedure is more effective than idling the engine at

used to remove soot from the DPF, and warmup the

no load. The engine should reach operating

Selective Catalyst Reduction (SCR system. The

temperature in a few minutes.

DPF traps both soot and ash. The ash is removed

through a manual cleaning process. Refer to

Avoid excess idling. Excessive idling causes carbon

Operation and Maintenance Manual, “Diesel

buildup, engine slobber and, soot loading of the

Particulate Filter - Clean” for more information on the

Diesel Particulate Filter (DPF. These issues are

service of the DPF.

harmful to the engine.

Regeneration Indicators

Gauge readings should be observed and the data

should be recorded frequently whilst the engine is

Regeneration Active - When

operating. Comparing the data over time will help to

illuminated, this indicator shows that

determine normal readings for each gauge.

the system is active. This indicator

Comparing data over time will also help detect

shows that elevated emission temperatures are

abnormal operating developments. Significant

changes in the readings should be investigated.

possible. This indicator will turn off when

regeneration is complete.

Engine Operation and the

DPF - This indicator will illuminate to

Aftertreatment System

show that regeneration is required. This

indicator will illuminate when “Time to

The exhaust gases and hydrocarbon particles from

Regen” is less than a pre-determined amount of

the engine first pass through the Diesel Oxidation

time.

Catalyst (DOC. Some of the gases and hydrocarbon

particles are oxidized as they pass through the DOC.

Regeneration Disabled - This indicator

The gases then pass through the Diesel Particulate

will illuminate to show that regeneration

Filter (DPF. The DPF collects the soot and any ash

has been disabled.

that is produced by the combustion in the engine.

During regeneration, the soot is converted into a gas

Regeneration Switch

and the ash remains in the DPF. The gases finally

pass through the Selective Catalytic Reduction

Force Regeneration - Press in the top

(SCR. Before the gases pass through the SCR,

switch for 2 seconds to begin

Diesel Exhaust Fluid (DEF is injected into the gas

regeneration.

stream. The DEF is controlled by the Pump

Electronic Unit (PEU. The mixtures of DEF and the

Disable Regeneration - Press in the

exhaust gas pass through the SCR reducing the NOx

bottom switch for 2 seconds to disable

in the exhaust emissions.

regeneration.

The engine software will control the amount of DEF

that will be required to keep the exhaust emission

Note: If equipped with a rocker style switch, the

compliant.

MIDDLE position of the regeneration switch is the

default position for automatic regeneration.

M0076814-03

Operation Section

Diesel Particulate Filter Regeneration

Note: If the engine start switch key is cycled or the

Disabled: When the regeneration system is in

“Force Regeneration” switch is pressed for longer

disabled mode, automatic regenerations will not be

than 2 seconds the system will no longer be disabled.

performed. The DPF indicator will illuminate if manual

When the “Force Regeneration” switch is pressed

regeneration is required. The “Time to Regen”

displayed on the performance screen will indicate

and “Time to Regen” is less than 8 hours,

that the time until the next regeneration will be

regeneration will begin if the machine is at low idle

required. However, the DPF indicator may illuminate

and is parked.

with time remaining on the display. When the DPF

indicator illuminates, the operator must perform

Note: If the engine start switch key is cycled whilst

manual regeneration.

the regeneration system is disabled via the “Disable

Regeneration” switch, press and hold the “Disable

Regeneration” switch for 2 seconds to reinitiate.

Regeneration Triggers

Regeneration may be required for the following

Modes of Regeneration

reasons:

Automatic: The Electronic Control Module (ECM)

Soot: The DPF will collect soot produced by the

uses multiple inputs from the engine and the machine

engine. Automatic regeneration will become active to

to determine the best time to perform automatic

reduce soot level.

regeneration. Automatic regenerations can take

place throughout the operating cycle of the engine.

Start-Up Regeneration: Start-up regeneration is

The regeneration active indicator will be illuminated

initiated by the ECM after a cold engine start. This

when regeneration is being performed. Interruptions

regeneration is performed to heat the system to a

of the regeneration are acceptable. If regeneration is

required temperature for Diesel Exhaust Fluid (DEF)

in progress and the regeneration needs to be

dosing to begin.

stopped, it is permissible to press the “Disable

SCR Maintenance: Regeneration is performed to

Regeneration” switch.

maintain the SCR system.

Note: Automatic adjustments of engine speed may

ARD Maintenance: Regeneration is performed to

be noticed during regenerations. If regeneration is

maintain the CRS system.

taking place and the engine is taken to low idle, the

engine speed may remain elevated to maintain the

regeneration.

Regeneration System Warning

Indicators

Note: If the machine returns to work whilst automatic

regeneration is active, the regeneration may be

stopped. The ECM will continue to monitor inputs to

determine the best time to restart the regeneration.

Manual: Manual regeneration is initiated by pressing

the “Force Regeneration” switch. Manual

regeneration will only be allowed if the “Time to

Regen” is less than 8 hours. If the “Force

Regeneration” switch is pressed before “Time to

Regen” is less than 8 hours, then “Regen not

Illustration 52

g02117258

Required” will be displayed. The machine must be

stationary, the parking brake must be applied, and

The DPF Indicator will illuminate solid when

the engine must be at low idle to perform manual

regeneration is required. Regeneration should be

regeneration.

performed as soon as possible.

Note: In some situations, the DPF indicator may stay

illuminated after regeneration ends. The illuminated

DPF indicator indicates that complete regeneration

has not been performed. Complete regeneration is

when the soot has been depleted or all the criteria for

one of the other regeneration types have been met. If

the DPF indicator stays illuminated, perform,

regeneration without interruption. The DPF indicator

will shut off when regeneration is complete.

M0076814-03

Operation Section

Engaging the Driven Equipment

If the soot load is above a threshold or “Time to

NOTICE

Regen” is 0 hours, then regeneration is required. The

The engine and emissions control system shall be

DPF indicator will illuminate and flash slowly. Engine

operated, used, and maintained in accordance with

power will be slightly derated. If the machine

the instructions provided. Failure to follow the instruc-

continues to operate without regeneration, derate will

tions could result in emissions performance that does

eventually reach 100%. Stop the machine and apply

not meet the requirements applicable to the category

the parking brake. With the engine at low idle, initiate

of the engine. No deliberate tampering with, or mis-

manual regeneration.

use of the engine emissions control system should

take place. Prompt action is critical to rectify any in-

correct operation, use, or maintenance of the emis-

sions control system.

Carbon Dioxide (CO₂) Emissions

Statement

Illustration 53

g03679876

Emissions regulations require that the value of the

CO2 emissions be reported to the end user. For this

Once the amount of soot collected in the DPF has

engine, 760 g/kWh, was determined to be the CO₂

reached a threshold or “Time to Regen” has been at

value during the EU type approval process. This

0 hours for a pre-determined time, the DPF indicator

value was recorded in EU type approval certificate.

will illuminate and flash at a fast rate. A red stop lamp

will illuminate solid.

This CO2 measurement results from testing over a

fixed test cycle, under laboratory conditions, with a

10 minutes after the illumination of the DPF indicator

parent engine representative of the engine family.

and red stop lamp the engine will Shut down. The

This value shall not imply or express any guarantee

engine can be restarted by cycling the engine start

of the performance of a particular engine.

switch key. The engine will return to the previous

derate state before shutdown.

i04038637

Once the amount of soot collected reaches a

threshold level or 6.4 hours of run time has passed

Engaging the Driven

since the red stop lamp was illuminated without

successful regeneration, the engine will have a 100%

Equipment

derate.

Once the amount of soot collected reaches a critical

threshold level, the regeneration will be locked out.

1. Operate the engine at one-half of the rated rpm,

Now, regeneration can only be performed by

when possible.

usingelectronic service tool (ET). The engine may be

restarted, but will only run for 3 minutes before

2. Engage the driven equipment without a load on the

shutting down again.

equipment, when possible.

A fault code will be active for any DPF system-related

Interrupted starts put excessive stress on the drive

issue. Follow the troubleshooting guide to rectify the

train. Interrupted starts also waste fuel. To get the

issue.

driven equipment in motion, engage the clutch

smoothly with no load on the equipment. This

If the DPF loses function, or is tampered with in any

method should produce a start that is smooth and

way, the check engine lamp, and an amber action (if

equipped) will illuminate. A fault code will also

easy. The engine rpm should not increase and the

annunciate. The lamps and fault code will remain

clutch should not slip.

active until the problem is rectified.

3. Ensure that the ranges of the gauges are normal

when the engine is operating at one-half of the

rated rpm. Ensure that all gauges operate

properly.

4. Increase the engine rpm to the rated rpm. Always

increase the engine rpm to the rated rpm before

the load is applied.

M0076814-03

Operation Section

Fuel Conservation Practices

5. Apply the load. Begin operating the engine at low

•

Ensure that the driven equipment is in good

load. Check the gauges and equipment for proper

working order.

operation. After normal oil pressure is reached and

•

Cold engines consume excess fuel. Utilize heat

the temperature gauge begins to move, the engine

from the jacket water system and the exhaust

may be operated at full load. Check the gauges

system, when possible. Keep cooling system

and equipment frequently when the engine is

components clean and keep cooling system

operated under load.

components in good repair. Never operate the

engine without water temperature regulators. All

Extended operation at low idle or at reduced load

these items will help maintain operating

may cause increased oil consumption and carbon

temperatures.

buildup in the cylinders. This carbon buildup

results in a loss of power and/or poor

performance.

i07677865

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

to attain optimum performance for the life of the

engine.

• Avoid spilling fuel.

Fuel expands when it 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 different fuels. Use

only the recommended fuels. Refer to the

Operations and Maintenance Manual, “Fuel

Recommendations” for further information.

• Avoid unnecessary idling.

Shut off the engine rather than allowing the engine to

idle for long periods of time.

• Observe the service indicator frequently. Keep the

air cleaner elements clean.

• Ensure that the turbocharger is operating

correctly. For more information refer to this

Operation and Maintenance Manual,

“Turbocharger - Inspect”

• Maintain a good electrical system.

One faulty battery cell will overwork the alternator.

This fault will consume excess power and excess

fuel.

• The belt should be in good condition. Refer to the

Systems Operation, Testing and Adjusting, “V-Belt

Test” for further information.

• Ensure that all the connections of the hoses are

tight. The connections should not leak.

M0076814-03

Operation Section

Engine Stopping

Leaving the machine unattended when the engine

i05798719

is running may result in personal injury or death.

Before leaving the machine operator station, neu-

Stopping the Engine

tralize the travel controls, lower the work tools to

the ground and deactivate all work tools, and

place the lever for the hydraulic lockout control

in the LOCKED position.

NOTICE

Stopping the engine immediately after it has been

working under load, can result in overheating and ac-

Note: Leaving the engine unattended while running

celerated wear of the engine components.

may result in property damage in the event of a

malfunction.

See the following stopping procedure, to allow the

engine to cool, and to prevent excessive tempera-

Turn the engine start switch to the OFF position.

tures in the turbocharger center housing, which could

cause oil coking problems.

Delayed Engine Shutdown - The

delayed engine shutdown indicator will

illuminate or the following text will be

1. While the machine is stopped, run the engine for 5

displayed, ENGINE COOLDOWN ACTIVE.

minutes at low idle. Idling the engine allows hot

areas of the engine to cool gradually.

Delayed engine shutdown will run whenever the

exhaust temperature is above a threshold at engine

Note: If the “Regen Active” indicator is illuminated,

shutdown. Delayed engine shutdown will run for a

do not shut off the engine. Refer to Operation and

minimum of 76 seconds and will continue to run until

the engine and system components are cooled. The

Maintenance Manual, “Monitoring System” for more

default maximum run time is 7 minutes.

information on indicators. (if equipped)

Note: An authorized dealer can change the

2. Turn the engine start switch to the OFF position

maximum run time value up to 30 minutes, but the

and remove the key.

default setting is 7 minutes.

Note: The engine may delay before completely

Note: To override delayed engine shutdown and stop

shutting down. Delayed engine shutdowns aid in

the engine, turn the engine start switch to the STOP

cooling the engine and after-treatment (if equipped)

position. Overriding delayed engine shutdown may

components.

reduce engine and system component life. A warning

message and/or audible alarm will be initiated and a

Delayed Engine Shutdown (If

fault code will be logged for improper engine

shutdown.

Enabled)

The Delayed Engine Shutdown allows the engine to

run for a time after the engine start switch key is

turned to the OFF position to cool the engine and

system components. The engine start switch key

may be removed.

Note: The DEF purge process will run for 2 minutes

once the engine is shut down and must complete.

The purge process may occur during delayed engine

shutdown. Do not turn off battery disconnect switch

during the purge process. Do not turn off the battery

power disconnect switch until the battery disconnect

switch indicator lamp has turned off. If the purge

process does not complete, a diagnostic code will

become active.

Note: There may be regulations that define the

requirements for the operator and/or support

personnel to be present when the engine is running.

M0076814-03

Operation Section

Manual Stop Procedure

i01465494

After Stopping Engine

Note: Before you check the engine oil, do not

operate the engine for at least 10 minutes in order to

allow the engine oil to return to the oil pan.

• Check the crankcase oil level. Maintain the oil

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

mark on the oil level gauge.

• If necessary, perform minor adjustments. Repair

any leaks and tighten any loose bolts.

Illustration 54

g02362719

• Note the service hour meter reading. Perform the

Note: At any time during a delayed engine shutdown,

maintenance that is in the Operation and

the engine start switch may be turned to the ON

Maintenance Manual, “Maintenance Interval

position. The engine may be placed back into

Schedule”.

service.

• Fill the fuel tank in order to help prevent

i05812522

accumulation of moisture in the fuel. Do not overfill

the fuel tank.

Manual Stop Procedure

NOTICE

Only use antifreeze/coolant mixtures recommended

in the Coolant Specifications that are in the Operation

NOTICE

and Maintenance Manual. Failure to do so can cause

Stopping the engine immediately after it has been

engine damage.

working under load can result in overheating and ac-

celerated wear of the engine components.

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

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

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

• If freezing temperatures are expected, check the

reduce and stabilize internal engine temperature be-

coolant for proper antifreeze protection. The

fore stopping the engine.

cooling system must be protected against freezing

to the lowest expected outside temperature. Add

Avoiding hot engine shutdowns will maximize turbo-

the proper coolant/water mixture, if necessary.

charger shaft and bearing life.

• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in

Note: Individual applications have different control

the instructions from the OEM.

systems. Ensure that the shutoff procedures are

understood. Use the following general guidelines in

order to stop the engine.

1. Remove the load from the engine so that the

engine has no more than 30% power.

2. Run the engine at the programmed low idle speed

for at least 3 minutes.

3. After the cool down period, turn the start switch to

the OFF position.

M0076814-03

Operation Section

Cold Weather Operation

• Cloud point

Cold Weather Operation

• Pour point

i07622821

• Cold Filter Plugging Point (CFPP)

Radiator Restrictions

The cloud point of the fuel is the temperature at

which waxes naturally found in the diesel fuel begin

to form crystals. The cloud point of the fuel must be

Perkins discourages the use of airflow restriction

below lowest ambient temperature to prevent filters

devices that are mounted in front of radiators. Airflow

from plugging.

restriction can cause the following conditions:

Pour point is the last temperature before the fuel flow

• High exhaust temperatures

stops and waxing of the fuel will start.

• Power loss

Cold Filter Plugging Point (CFPP) is a temperature at

which a particular fuel will pass through a

• Excessive fan usage

standardized filtration device. This CFPP gives an

estimate of the lower operability temperature of fuel

• Reduction in fuel economy

Be aware of these properties when diesel fuel is

Reducing air flow over components will also affect

purchased. Consider the average ambient air

under hood temperatures. Reducing air flow can

temperature for the engines application. Engines that

increase surface temperatures during an

are fueled in one climate may not operate well if the

aftertreatment regeneration and could affect

engines are shipped to colder climate. Problems can

component reliability.

result due to changes in temperature.

If an airflow restriction device must be used, the

Before troubleshooting for low power or for poor

device should have a permanent opening directly in

performance in the winter, check the fuel for waxing

line with the fan hub. The device must have a

minimum opening dimension of at least 770 cm²

The following components can provide a means of

(120 in²).

minimizing fuel waxing problems in cold weather:

A centered opening that is directly in line with the fan

• Fuel heaters, which may be an OEM option

hub is specified to prevent an interrupted airflow on

the fan blades. Interrupted airflow on the fan blades

• Fuel line insulation, which may be an OEM option

could cause a fan failure.

Winter and arctic grades of diesel fuel are available in

Perkins recommends a warning device for the inlet

the countries and territories with severe winters. For

manifold temperature and/or the installation of an

more information refer to the Operation and

inlet air temperature gauge. The warning device for

Maintenance Manual, “Fuel For Cold-Weather

the inlet manifold temperature should be set at 75 °C

Operation”

(167 °F). The inlet manifold air temperature should

not exceed 75 °C (167 °F). Temperatures that

Another important fuel property which can affect cold

exceed this limit can cause power loss and potential

start and operation of diesel engine is Cetane

engine damage.

number. Detail and requirements of this property are

given in this Operation and Maintenance Manual,

“Fluid Recommendations”.

i07818744

i06093465

Fuel and the Effect from Cold

Weather

Fuel Related Components in

Cold Weather

Note: Only use grades of fuel that are recommended

by Perkins. Refer to this Operation and Maintenance

Manual, “Fluid Recommendations”.

Fuel Tanks

Properties of the diesel fuel can have a significant

Condensation can form in partially filled fuel tanks.

effect on the engine cold start capability. It is critical

Top off the fuel tanks after operating the engine.

that the low temperature properties of diesel fuel are

acceptable for the minimum ambient temperature the

engine is expected to see in operation.

Following properties are used to define fuels low

temperature capability:

M0076814-03

Operation Section

Fuel Related Components in Cold Weather

Fuel tanks should contain some provision for draining

water and sediment from the bottom of the tanks.

Some fuel tanks use supply pipes that allow water

and sediment to settle below the end of the fuel

supply pipe.

Some fuel tanks use supply lines that take fuel

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

equipped with this system, regular maintenance of

the fuel system filter is important.

Drain the water and sediment from any fuel storage

tank at the following intervals:

• Weekly

• Oil changes

• Refueling of the fuel tank

This draining will help prevent water and/or sediment

from being pumped from the fuel storage tank and

into the engine fuel tank.

Fuel Heaters

Fuel heaters help to prevent fuel filters from plugging

in cold weather due to waxing. A fuel heater should

be installed in order for the fuel to be heated before

the fuel enters the primary fuel filter.

Select a fuel heater that is mechanically simple, yet

adequate for the application. The fuel heater should

also help to prevent overheating of the fuel. High fuel

temperatures reduce engine performance and the

availability of engine power. Choose a fuel heater

with a large heating surface. The fuel heater should

be practical in size. Small heaters can be too hot due

to the limited surface area.

Disconnect the fuel heater in warm weather.

Note: Fuel heaters that are controlled by the water

temperature regulator or self-regulating fuel heaters

should be used with this engine. Fuel heaters that are

not controlled by the water temperature regulator can

heat the fuel in excess of 65° C (149° F). A loss of

engine power can occur if the fuel supply

temperature exceeds 37° C (100° F).

Note: Heat exchanger type fuel heaters should have

a bypass provision in order to prevent overheating of

the fuel in warm-weather operation.

For further information on fuel heaters, consult your

Perkins distributor .

M0076814-03

Maintenance Section

Refill Capacities

Maintenance Section

NOTICE

These recommendations are subject to change with-

out notice. Contact your local Perkins distributor for

the most up-to-date recommendations.

Refill Capacities

i07490664

Diesel Fuel Requirements

Fluid Recommendations

Perkins is not in a position to continuously evaluate

and monitor all worldwide distillate diesel fuel

(General Fuel Information)

specifications that are published by governments and

technological societies.

The "Perkins Specification for Distillate Diesel Fuel"

•

Glossary

provides a known reliable baseline to judge the

expected performance of distillate diesel fuels that

•

ISO

International Standards Organization

are derived from conventional sources.

•

ASTM

American Society for Testing and

Satisfactory engine performance depends on the use

Materials

of a good quality fuel. The use of a good quality fuel

will give the following results: long engine life and

•

HFRR

High Frequency Reciprocating Rig

acceptable exhaust emissions levels. The fuel must

for Lubricity testing of diesel fuels

meet the minimum requirements that are stated in

the table 3 .

•

FAME

Fatty Acid Methyl Esters

NOTICE

•

CFR

Co-ordinating Fuel Research

The footnotes are key part of the Perkins "Specifica-

tion for Distillate Diesel Fuel" Table. Read ALL of the

•

ULSD

Ultra Low Sulfur Diesel

footnotes.

•

RME

Rape Methyl Ester

•

SME

Soy Methyl Ester

•

EPA

Environmental Protection Agency of

the United States

•

PPM

Parts Per Million

•

DPF

Diesel Particulate Filter

•

v/v

(volume of solute)/(volume of solution)

•

CFPP

Cold Filter Plugging Point

•

BTL

Biomass to liquid

•

GTL

Gas to liquid

•

CTL

Coal to liquid

•

HVO

Hydrotreated Vegetable Oil

General Information

NOTICE

Every attempt is made to provide accurate, up-to-

date information. By use of this document you agree

that Perkins Engines Company Limited is not respon-

sible for errors or omissions.

M0076814-03

Maintenance Section

General Fuel Information

Table 3

"Perkins Specification for Distillate Diesel Fuel"

Property

UNITS

Requirements

“ASTM”Test

“ISO/Other”Test

Aromatics

%Volume

35% maximum

“D1319”

“ISO 3837”

Ash

%Weight

0.01% maximum

“D482”

“ISO 6245”

Carbon Residue on 10%

%Weight

0.20% maximum

“D524”

“ISO 4262”

Bottoms

Cetane Number⁽¹⁾

40 minimum in North

“D613 or D6890”

“ISO 5165”

America

45 minimum in European

Union

Cloud Point

°C

The cloud point must not

“D2500”

“ISO 3015”

exceed the lowest expected

ambient temperature.

Copper Strip Corrosion

No. 3 maximum

“D130”

“ISO 2160”

Distillation

°C

50% at 250° C (482° F)

“D86”

“ISO 3405”

minimum

90% at 350° C (662° F)

maximum

Density at 15 °C (59 °F)⁽²⁾

kg/M³

800 minimum and 860

No equivalent test

“ISO 3675”“ISO 12185”

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⁽³⁾

%mass

0.0015 % maximum

“D5453”

“ISO 20846”

Kinematic Viscosity⁽⁴⁾

MM2/S (cSt)

The viscosity of the fuel that

“D445”

“ISO 3405”

is delivered to the fuel injec-

tion pump. 1.4 minimum

and 4.5 maximum

Water and sediment

% weight

0.05% maximum

“D1796”

“ISO 3734”

Water

% weight

0.02% maximum

“D1744”

No equivalent test

Sediment

% weight

0.05% maximum

“D473”

“ISO 3735”

Gums and Resins⁽⁵⁾

mg/100mL

10 mg per 100 mL

“D381”

“ISO 6246”

maximum

Lubricity correctedwear

0.52 maximum

“D6079”

“ISO 12156-1”

scar diameter at 60 °C

(140 °F).⁽⁶⁾

Fuel Cleanliness⁽⁷⁾

“ISO 18/16/13”

“D7619”

“ISO 4406”

Trace Metals⁽⁸⁾

mg/mg

Max 1 or non-detectable

“D7111”

Oxidation Stability

g/m^3

Max 25

“D2274”

“ISO 12205”

Hours⁽⁹⁾

Min 20

“EN 15751”

⁽¹⁾ A fuel with a higher cetane number than 45 is recommended to operate at a higher altitude in cold weather

⁽²⁾ Density range allowed includes summer and winter diesel fuel grades.

(continued)

M0076814-03

Maintenance Section

General Fuel Information

(Table 3, contd)

⁽³⁾ Ultra Low Sulfur Diesel Fuel with sulphur content less than 0.0015 percent 15 PPM (mg/kg) must be used. Use of diesel fuel with higher than

15 PPM sulphur limit in these engines will harm or permanently damage emissions control systems. Also, use of diesel fuel with higher than

15 PPM sulphur limit can shorten service interval.

⁽⁴⁾ 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 “1.4 cSt” at the fuel injection pump.

⁽⁵⁾ Follow the test conditions and procedures for gasoline (motor).

⁽⁶⁾ The lubricity of a fuel is a concern with low sulfur and ultra low sulfur fuel. Fuel with higher wear scar diameter than 0.52 mm (0.0205 inch)

will lead to reduced service life and premature failure of the fuel system. Refer to the lubricity section of this “Operation and Maintenance

Manual” Fluid Recommendations for more information.

⁽⁷⁾ Recommended cleanliness level for fuel as dispensed into machine or engine fuel tank is“ISO 18/16/13”or cleaner as per “ISO 4406”. Refer

to the “Contamination Control Recommendations for Fuels.

⁽⁸⁾ Examples of trace metals include but not limited to Cu, Fe, Mn, Na, P, Pb, Si, and Zn. Use of metal-based additives is not allowed.

⁽⁹⁾ Additional limit for fuel containing FAME. Fuel containing more than 2% v/v FAME must meet both tests.

Note: The owner and the operator of the engine has

the responsibility of using the fuel that is prescribed

by the EPA and other appropriate regulatory

agencies.

NOTICE

Operating with fuels that do not meet the Perkins rec-

ommendations can cause the following effects: Start-

ing difficulty, reduced fuel filter service life, poor

combustion, deposits in the fuel injectors, signifi-

cantly reduce service life of the fuel system. Also, the

creation of deposits in the combustion chamber and

reduced service life of the engine.

NOTICE

Illustration 55

g02157153

The Perkins 2000 series of diesel engine must be op-

erated using Ultra Low Sulfur Diesel. The sulphur

Illustration 55 is a representation of the label that will

content of this fuel must be lower than 15 PPM. This

be installed next to the fuel filler cap on the fuel tank

fuel complies with the emissions regulations that are

of the application.

prescribed by the Environmental Protection Agency

of the United States.

The fuel specifications that are listed in the table 4

are released as acceptable to use on all 2000 series

European ULSD 0.0010 percent (≤10ppm (mg/kg))

of engine.

sulfur fuel is required by regulation for use in engines

certified to European nonroad Stage V type-approved

nonroad engines. Additionally, the Cetane number

should be less than 45, and the bio-diesel content

should be greater than 20% volume/volume.

Table 4

Acceptable Fuel Specification for the 2000 Series of Engines⁽¹⁾

Fuel Specification

Comments

EN590

European Automotive Diesel Fuel (DERV)

“ASTM D975 GRADE 1D S15”

“North American Light Distillate Diesel fuel with less than 15 PPM sul-

fur level”

“ASTM D975 GRADE 2D S15”

“North American Middle Distillate general-purpose Diesel fuel with less

than 15 PPM sulfur level”

“JIS K2204”

“Japanese Diesel Fuel” Must meet the requirements that are stated in

the lubricity section of this “Operation and Maintenance Manual” Fluid

Recommendations.

(continued)

M0076814-03

Maintenance Section

General Fuel Information

(Table 4, contd)

“BS 2869: 2010 CLASS A2 or EU equivalent”

UK Off-Road Diesel fuel

“CEN TS15940”

“Paraffinic diesel fuel from synthesis or hydrotreatment”, “Biomass-to-

liquid” (BTL), “Gas-to-liquid” (GTL), called Hydrotreated Vegetable Oil

(HVO). Refer to the Renewable and Alternative Fuels section of this

“Operation and Maintenance Manual” Fluid Recommendations for

more information.

B20 Biodiesel Blend

Refer to the Recommendation for Biodiesel and Using B20 section of

this “Operation and Maintenance Manual” Fluid Recommendations for

more information.

⁽¹⁾ All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel.

Diesel Fuel Characteristics

Perkins recommends kinematic viscosities of 1.4 and

4.5 mm2/sec that is delivered to the fuel injection

Cetane Number

pump. If a fuel with a low viscosity is used, cooling of

the fuel may be required to maintain 1.4 cSt or

Cetane number is a measure of the ignition quality of

greater viscosity at the fuel injection pump. Fuels with

diesel fuel. Fuel that has a higher cetane number will

a high viscosity might require fuel heaters to lower

give a shorter ignition delay and will produce a better

the viscosity to 4.5 cSt at the fuel injection pump.

ignition quality. Cetane numbers are derived for fuels

against proportions of cetane and

Density

heptamethylnonane in the standard CFR engine.

Refer to “ISO 5165” for the test method.

Density is the mass of the fuel per unit volume at a

In Europe for non-road Stage V emissions

specific temperature. This parameter has a direct

regulations require minimum cetane number of 45. In

influence on engine performance and a direct

influence on emissions. This influence determines

the North America, minimum cetane number

requirement is 40.

from a heat output given injected volume of fuel. This

parameter is quoted in the following kg/m³ at 15 °C

Cetane number affect engine cold start ability,

(59 °F).

exhaust emissions, combustion noise, and altitude

performance. Fuel with a higher cetane number is

Perkins recommends a density of 841 kg/m³ to

desirable and recommended. This is particularly

obtain the correct power output. Lighter fuels are

important for operations in cold weather and at high

acceptable but these fuels will not produce the rated

altitude.

power.

Viscosity

Sulfur

The level of sulfur is governed by emissions

Viscosity is the property of a liquid of offering

legislations. Regional regulation, national

resistance to shear or flow. Viscosity decreases with

regulations, or international regulations can require a

increasing temperature. This decrease in viscosity

fuel with a specific sulfur limit. The sulfur content of

follows a logarithmic relationship for normal fossil

the fuel and the fuel quality must comply with all

fuel. The common reference is to kinematic viscosity.

existing local regulations for emissions.

Kinematic viscosity is the quotient of the dynamic

viscosity that is divided by the density. The

Perkins 2000 series diesel engines have been

determination of kinematic viscosity is normally by

designed to operate only with Ultra Low Sulfur Diesel

readings from gravity flow viscometers at standard

(ULSD) fuel. By using the test methods “ASTM

temperatures. Refer to “ISO 3104” for the test

D5453, or ISO 20846”, the content of sulfur in ULSD

method.

fuel must be below 15 PPM (mg/kg) or 0.0015%

mass.

The viscosity of the fuel is significant because fuel

serves as a lubricant for the fuel system components.

In the USA, EPA regulations require the use ULSD

Fuel must have sufficient viscosity to lubricate the

fuel with less than 0.0015 percent (15 PPM) (mg/kg))

fuel system in both extremely cold temperatures and

sulfur content.

extremely hot temperatures. If the kinematic viscosity

of the fuel is lower than “1.4 cSt” at the fuel injection

In Europe, sulfur free diesel fuels with sulphur

pump, damage to the fuel injection pump can occur.

content less than 0.0010 percent (10 PPM) (mg/kg))

This damage can be excessive scuffing and seizure.

is required by regulation for use in engines certified to

Low viscosity may lead to difficult hot restarting,

EU nonroad Stage V emissions.

stalling, and loss of performance. High viscosity may

result in seizure of the pump.

M0076814-03

Maintenance Section

General Fuel Information

Raw pressed vegetable oils are NOT acceptable for

NOTICE

use as a fuel in any concentration in compression

Use of diesel fuel with higher than 15 PPM sulphur

engines. Without esterification, these oils solidify in

limit in these engines will harm or permanently dam-

the crankcase and the fuel tank. These fuels may not

age emissions control systems and/or shorten serv-

be compatible with many of the elastomers that are

ice interval.

used in engines that are manufactured today. In

original forms, these oils are not suitable for use as a

fuel in compression engines. Alternate base stocks

Lubricity

for biodiesel may include animal tallow, waste

cooking oils, or various other feedstocks. To use any

Lubricity is the capability of the fuel to prevent pump

of the products that are listed as fuel, the oil must be

wear. The fluids lubricity describes the ability of the

esterified.

fluid to reduce the friction between surfaces that are

under load. This ability reduces the damage that is

Fuel made of 100 percent FAME is generally referred

caused by friction. Fuel injection systems rely on the

to as B100 biodiesel or neat biodiesel.

lubricating properties of the fuel. Until fuel sulfur limits

were mandated, the fuels lubricity was generally

Biodiesel can be blended with distillate diesel fuel.

The blends can be used as fuel. The most commonly

believed to be a function of fuel viscosity.

available biodiesel blends are B5, which is 5 percent

biodiesel and 95 percent distillate diesel fuel. B20,

The lubricity has particular significance to the current

which is 20 percent biodiesel and 80 percent distillate

ultra low sulfur fuel, and low aromatic fossil fuels.

These fuels are made to meet stringent exhaust

diesel fuel.

emissions.

Note: The percentages given are volume-based.

The lubricity of these fuels must not exceed wear

scar diameter of 0.52 mm (0.0205 inch). The fuel

The U.S. distillate diesel fuel specification “ASTM

lubricity test must be performed on an HFRR,

D975” includes up to B5 (5 percent) biodiesel.

operated at 60 °C (140 °F). Refer to “ISO 12156-1”.

European distillate diesel fuel specification EN590

includes up B7 (7 percent) biodiesel.

NOTICE

The fuels system has been qualified with fuel having

Note: Engines that are manufactured by Perkins are

lubricity up to 0.52 mm (0.0205 inch) wear scar diam-

certified by use of the prescribed Environmental

eter as tested by “ISO 12156-1”. Fuel with higher

Protection Agency (EPA) and European Certification

wear scar diameter than 0.52 mm (0.0205 inch) will

lead to reduced service life and premature failure of

fuels. Perkins does not certify engines on any other

the fuel system.

fuel. The user of the engine has the responsibility of

using the correct fuel that is recommended by the

manufacturer and allowed by the EPA and other

Fuel additives can enhance the lubricity of a fuel.

appropriate regulatory agencies.

Contact your fuel supplier for those circumstances

when fuel additives are required. Your fuel supplier

Specification Requirements

can make recommendations for additives to use, and

for the proper level of treatment.

The neat biodiesel must conform to the latest

“EN14214 or ASTM D6751” (in the USA). The

Distillation

biodiesel can only be blended in mixture of up to 20%

by volume in acceptable mineral diesel fuel meeting

Distillation is an indication of the mixture of different

latest edition of “EN590 or ASTM D975 S15”

hydrocarbons in the fuel. A high ratio of lightweight

designation.

hydrocarbons can affect the characteristics of

combustion.

In United States Biodiesel blends of B6 to B20 must

meet the requirements listed in the latest edition of

“ASTM D7467” (B6 to B20) and must be of an API

Recommendation for Biodiesel and

gravity of 30-45.

Using B20

In North America biodiesel and biodiesel blends must

Biodiesel is a fuel that can be defined as mono-alkyl

be purchased from the BQ-9000 accredited

esters of fatty acids. Biodiesel is a fuel that can be

producers and BQ-9000 certified distributors.

made from various feedstocks. The most commonly

available biodiesel in Europe is Rape Methyl Ester

European distillate diesel fuel specification “EN

16709:2015” includes up to B20 (20 percent)

(RME). This biodiesel is derived from rapeseed oil.

biodiesel. Any diesel fuel in Europe may contain up to

Soy Methyl Ester (SME) is the most common

biodiesel in the United States. This biodiesel is

B20.

derived from soybean oil. Soybean oil or rapeseed oil

are the primary feedstocks. These fuels are together

known as Fatty Acid Methyl Esters (FAME).

M0076814-03

Maintenance Section

General Fuel Information

In other areas of the world, the use of biodiesel that is

Note: Perkins Fuel Cleaner (part number T400012)

BQ-9000 accredited and certified, or that is

is most effective in cleaning and preventing the

accredited and certified by a comparable biodiesel

formation of deposits. Perkins Diesel Fuel

quality body to meet similar biodiesel quality

Conditioner helps to limit deposit issues by improving

standards is required.

the stability of biodiesel and biodiesel blends. For

more information refer to Perkins Diesel Fuel

Engine Service Requirements

Cleaner.

Aggressive properties of biodiesel fuel may cause

Biodiesel fuel contains metal contaminants (sodium,

debris in the fuel tank and fuel lines. The aggressive

potassium, calcium, and/or magnesium) that form

properties of biodiesel will clean the fuel tank and fuel

ash products upon combustion in the diesel engine.

lines. This cleaning of the fuel system can

The ash can have an impact on the life and

prematurely block the fuel filters. Perkins recommend

performance of aftertreatment emissions control

that after the initial usage of B20 biodiesel blended

devices and can accumulate in DPF. The ash

fuel the fuel filters must be replaced at 50 hours.

accumulation may cause the need for more frequent

ash service intervals and cause loss of performance

Glycerides present in biodiesel fuel will also cause

fuel filters to become blocked more quickly. Therefore

General Requirements

the regular service interval should be reduced to 250

hours.

Biodiesel has poor oxidation stability, which can

result in long-term problems in the storage of

When biodiesel fuel is used, crank case oil and

aftertreatment systems may be influenced. This

biodiesel. Biodiesel fuel should be used within 6

months of manufacture. Equipment should not be

influence is due to the chemical composition and

stored with the B20 biodiesel blends in the fuel

characteristics of biodiesel fuel, such as density and

system for longer than 3 months.

volatility, and to chemical contaminants that can be

present in this fuel, such as alkali and alkaline metals

Due to poor oxidation stability and other potential

(sodium, potassium, calcium, and magnesium).

issues, it is strongly recommended that engines with

limited operational time either not use B20 biodiesel

• Crankcase oil fuel dilution can be higher when

blends or, whilst accepting some risk, limit biodiesel

biodiesel or biodiesel blends are used. This

blend to a maximum of B5. Examples of applications

increased level of fuel dilution when using

that should limit the use of biodiesel are the following:

biodiesel or biodiesel blends is related to the

Standby Generator sets and certain emergency

typically lower volatility of biodiesel. In-cylinder

vehicles.

emissions control strategies utilized in many of the

industrial latest engine designs may lead to a

For standby generator sets and emergency vehicles

that cannot avoid use of biodiesel blends fuel quality

higher level of biodiesel concentration in the

in the engine fuel tank must be sampled and checked

sump. The long-term effect of biodiesel

monthly. Test should include acid number

concentration in crankcase oil is unknown

(EN14104), oxidation stability (EN 15751 commonly

currently.

know as the Rancimant test), and sediment

(ISO12937). For standby generator sets oxidation

• Perkins recommend the use of oil analysis to

stability of biodiesel blend must be 20 hours or more

check the quality of the engine oil if biodiesel fuel

as per EN 15751. If the test shows that the fuel has

is used. Ensure that the level of biodiesel in the

degraded, fuel tank must be drained and engine

fuel is noted when the oil sample is taken.

flashed by running with the fresh high-quality diesel

fuel.

Performance Related Issues

Perkins strongly recommended that seasonally

Due to the lower energy content than the standard

operated engines have the fuel systems, including

distillate fuel B20 will cause a power loss in order of 2

fuel tanks, flashed with conventional diesel fuel

to 4 percent. In addition, over time the power may

before prolonged shutdown periods. An example of

deteriorate further due to deposits in the fuel

an application that should seasonally flush the fuel

injectors.

system is a combine harvester.

Biodiesel and biodiesel blends are known to cause

Microbial contamination and growth can cause

an increase in fuel system deposits, most significant

corrosion in the fuel system and premature plugging

of which are deposits within the fuel injector. These

of the fuel filter. Consult your supplier of fuel for

deposits can cause a loss in power due to restricted

assistance in selecting appropriate anti-microbial

or modified fuel injection or cause other functional

additive.

issues associated with these deposits.

Water accelerates microbial contamination and

growth. When biodiesel is compared to distillate

fuels, water is naturally more likely to exist in the

biodiesel. Therefore check frequently and if

necessary, drain the water separator.

M0076814-03

Maintenance Section

General Fuel Information

Materials such as brass, bronze, copper, lead, tin,

Fuel that complies with “EN590” CLASS 4 can be

and zinc accelerate the oxidation process of the

used at temperatures as low as -44 °C (-47.2 °F).

biodiesel fuel. The oxidation process can cause

Refer to “EN590” for a detailed discretion of the

deposits formation therefore these materials must not

physical properties of the fuel.

be used for fuel tanks and fuel lines.

The diesel fuel “ASTM D975 1-D” used in the United

States of America may be used in very cold

Renewable and Alternative Fuels

temperatures that are below -18 °C (-0.4 °F).

Perkins supports development and use of renewable

Aftermarket Fuel Additives

fuels through sustainability initiatives. In recent years

various forms of renewable and alternative

(synthetic) diesel fuels have started to emerge.

NOTICE

Perkins does not warrant the quality or performance

Synthetic diesel fuels are produced by gasification of

of non-Perkins fluids and filters.

various feedstock and then synthesis to liquid to

obtain paraffinic diesel fuel. Based on the feedstock

When auxiliary devices, accessories, or consum-

used these fuels are commonly referred to as

ables (filters, additives) which are made by other

Biomass to liquid (BTL), Gas to liquid (GTL) and Coal

manufacturers are used on Perkins products, the

to liquid (CTL). Hydrotreating of vegetable oils and

Perkins warranty is not affected simply because of

animal fats is another emerging process for

such use.

production of bio based diesel fuel called

Hydrotreated Vegetable Oil (HVO).

However, failures that result from the installation

or use of other manufacturers devices, accesso-

BTL and HVO fuels are considered to be low carbon

ries, or consumables are NOT Perkins defects.

fuels as they reduce carbon foot print compared to

Therefore, the defects are NOT covered under the

Perkins warranty.

fossil fuels and are commonly referred to as

renewable fuels. These fuels must not be confused

with biodiesel FAME which is fundamentally different

Supplemental diesel fuel additives are not generally

fuel and is discussed in a separate section in this

recommended. This recommendation is due to

potential damage to the fuel system or the engine.

manual.

Your fuel supplier or the fuel manufacturer will add

These paraffinic diesel fuels have virtually no sulphur

the appropriate supplemental diesel fuel additives.

or aromatics and have very high cetane numbers

which enable very clean burning and efficient engine

Perkins recognizes the fact that additives may be

operation. Chemically these fuels are similar to diesel

required in some special circumstances.

fuel derived from petroleum.

Note: Some anti-corrosion additives can lead to

Paraffinic diesel fuels are considered as acceptable

injector fouling, this fouling can cause the injector to

to use as a directed replacement to petroleum diesel

operate incorrectly.

or as a blendstock for petroleum diesel fuel in Perkins

diesel engines provided they meet latest edition of

Contact your fuel supplier for those circumstances

the paraffinic diesel fuel specification “CENTS

when fuel additives are required. Your fuel supplier

15940”. The fuel should also meet requirements

can recommend the appropriate fuel additive and the

described in table 3 , Perkins Specification for

correct level of treatment.

Distillate Diesel Fuel, EN590, or latest ASTM D975

specification with the exception of density, which is

Note: For the best results, your fuel supplier should

inherently lower for paraffinic fuels. Due to lower

treat the fuel when additives are required. The

density, some rated power loss might be

treated fuel must meet the requirements that are

noticeable.

stated in table 3 .

Ensure that the fuel has got appropriate cold flow

Perkins Diesel Fuel System Cleaner

properties (cloud point and CFPP) for the minimum

statistical ambient temperature the engine is

Perkins Fuel Cleaner (part number T400012) is the

expected to see in the operation. The fuel must also

only fuel cleaner that is recommended by Perkins.

meet lubricity requirements as specified in the

lubricity section of this “Operation and Maintenance

If biodiesel or biodiesel blends of fuel are to be used,

Manual” Fluid Recommendations

Perkins require the use of Perkins fuel cleaner. The

use of the fuel is to remove deposits within the fuel

Fuel for Cold-Weather Operation

system that is created with the use of biodiesel. For

more information on the use of biodiesel and

The European standard “EN590” contains climate

biodiesel blends refer to Recommendation for

Biodiesel and Using B20.

dependant requirements and a range of options. The

options can be applied differently in each country.

There are five classes that are given to arctic

climates and severe winter climates. 0, 1, 2, 3 and 4.

M0076814-03

Maintenance Section

General Fuel Information

Perkins fuel cleaner will remove deposits that can

•

Fill fuel tanks with fuels of “ISO 18/16/13”

form in the fuel system with the use of biodiesel and

cleanliness level or cleaner, in particular for

biodiesel blends. These deposits can create a loss of

engines with common rail and unit injection

power and engine performance.

systems. When you refuel the tank, filter the fuel

through a 4 µm absolute filter (Beta 4 = 75 up to

Once the fuel cleaner has been added to the fuel, the

200) to reach the recommended cleanliness level.

deposits within the fuel system are removed after 30

This filtration should be installed at the device that

hours of engine operation. For maximum results,

dispenses the fuel to the fuel tank. In addition,

continue to use the fuel cleaner for up to 80 hours.

Perkins fuel cleaner can be used on an on-going

filtration at the dispensing point should remove

basis with no adverse impact on engine or fuel

water to ensure that fuel is dispensed at 500 ppm

system durability.

water or less.

Details instruction on the rate of which the fuel

•

Perkins recommends the use of bulk fuel filter /

cleaner is to be used are on the container.

coalescer units which clean the fuel of both

particulate contamination and water in a single

Note: Perkins fuel cleaner is compatible with existing

pass.

and U.S. EPA Tier 4 nonroad certified diesel engine

emission control catalysts and particulate filters.

•

Ensure that you use Perkins Advanced Efficiency

Perkins fuel system cleaner contains less than 15

Fuel Filters. Change your fuel filters per

ppm of sulfur and is acceptable for use with ULSD

recommended service requirements or as needed.

fuel.

•

Drain your water separators daily.

Contamination Control

•

Drain your fuel tanks of sediment and water per

Recommendations for Fuels

the Operation and Maintenance Manual

instructions.

Fuels of “ISO 18/16/13” cleanliness level or cleaner

as dispensed into the engine or application fuel tank

•

Install and maintain a properly designed bulk filter

should be used. This action will reduce risk of power

/ coalescer filtration system. Continuous bulk

loss, fuel system failures, and related down time of

filtration systems may be required to ensure that

engines. This cleanliness level is important for new

dispensed fuel meets the cleanliness target.

fuel system designs such as common rail injection

Consult your Perkins distributor for availability of

systems and unit injectors. These fuels systems

bulk filtration products.

utilize higher fuel injection pressures and have tight

clearances between moving parts to meet required

•

Centrifugal filters may need to be used as a pre-

stringent emissions regulations. Peak injection

filter with fuel that is severely contaminated with

pressures in current fuel injection systems may

gross amounts of water and/or large particulate

exceed 2000 bar (29000 psi). Clearances in these

contaminants. Centrifugal filters can effectively

systems are less than 5 µm. As a result, particle

remove large contaminants. Centrifugal filters may

contaminants as small as 4 µm can cause scoring

and scratching of internal pump and injector surfaces

not be able to remove the small abrasive particles

and of injector nozzles.

required to achieve the recommended “ISO”

cleanliness level. Bulk filter / coalescers are

Water in the fuel causes cavitation, corrosion of fuel

necessary as a final filter to achieve the

system parts, and provides an environment where

recommended cleanliness level.

microbial growth in the fuel can flourish. Other

sources of fuel contamination are soaps, gels, or

•

Install desiccant type breathers of 4 µm or less

other compounds that may result from undesirable

absolute efficiency with the ability to remove water

chemical interactions in the fuels, particularly in

on bulk storage tanks.

ULSD. Gels and other compounds can also form in

biodiesel fuel at low temperatures or if biodiesel is

•

Follow proper practices of fuel transportation.

stored for extended periods. The best indication of

Filtration from the storage tank to the application

microbial contamination, fuel additives, or cold

promotes the delivery of clean fuel. Fuel filtration

temperature gel is rapid filter plugging of bulk fuel

can be installed at each transport stage to keep

filters or application fuel filters.

the fuel clean.

To reduce downtime due to contamination, follow

these fuel maintenance guidelines.

•

Cover, protect, and ensure cleanliness of all

connection hoses, fittings, and dispensing

• Use high-quality fuels per recommended and

nozzles.

required specifications

M0076814-03

Maintenance Section

Fluid Recommendations

Consult your local Perkins distributor for additional

Note: The water must be used with an inhibitor to

information on Perkins designed and produced

protect the engine.

filtration products.

Distilled water or deionized water is

recommended for use in engine cooling systems.

i07675883

DO NOT use the following types of water in cooling

Fluid Recommendations

systems: Hard water, softened water that has been

conditioned with salt and sea water.

If distilled water or deionized water is not available,

use water with the properties that are listed in Table 5

General Coolant Information

Table 5

NOTICE

Acceptable Water

Never add coolant to an overheated engine. Engine

damage could result. Allow the engine to cool first.

Property

Maximum Limit

Chloride (Cl)

40 mg/L

NOTICE

Sulfate (SO4)

100 mg/L

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

with below freezing temperatures, the cooling system

Total Hardness

170 mg/L

must be either protected to the lowest outside tem-

perature or drained completely to prevent damage.

Total Solids

340 mg/L

Acidity

pH of 5.5 to 9.0

NOTICE

Frequently check the specific gravity of the coolant

For a water analysis, consult one of the following

for proper freeze protection or for anti-boil protection.

sources:

Clean the cooling system for the following reasons:

• Local water utility company

• Contamination of the cooling system

• Agricultural agent

• Overheating of the engine

• Independent laboratory

• Foaming of the coolant

Additives

Additives help to protect the metal surfaces of the

NOTICE

cooling system. A lack of coolant additives or

Never operate an engine without water temperature

insufficient amounts of additives enable the following

regulators in the cooling system. Water temperature

conditions to occur:

regulators help to maintain the engine coolant at the

proper operating temperature. Cooling system prob-

• Corrosion

lems can develop without water temperature

regulators.

• Formation of mineral deposits

• Rust

Many engine failures are related to the cooling

system. The following problems are related to cooling

• Scale

system failures: Overheating, leakage of the water

pump and plugged radiators or heat exchangers.

• Foaming of the coolant

These failures can be avoided with correct cooling

Many additives are depleted during engine operation.

system maintenance. Cooling system maintenance is

These additives must be replaced periodically.

as important as maintenance of the fuel system and

the lubrication system. Quality of the coolant is as

Additives must be added at the correct concentration.

important as the quality of the fuel and the lubricating

Over concentration of additives can cause the

oil.

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

enable the following problems to occur:

Coolant is normally composed of three elements:

Water, additives, and glycol.

• Formation of gel compounds

Water

• Reduction of heat transfer

Water is used in the cooling system to transfer heat.

• Leakage of the water pump seal

M0076814-03

Maintenance Section

Fluid Recommendations

• Plugging of radiators, coolers, and small passages

Note: Some commercially available coolants are

based on alternative fluids, such as 1, 3-propanediol

Glycol

(beta-propylene glycol, PDO), glycerin (glycerol) or

mixtures of these alternatives with ethylene/

Glycol in the coolant helps to provide protection

propylene glycols. At the time of publication of this

against the following conditions:

document no industry standard exists for coolants

based on these chemicals. Until such standard/

• Boiling

specifications are published and evaluated by

Perkins, use of PDO, glycerine or other alternative

• Freezing

coolants is not recommended in Perkins diesel

engines.

• Cavitation of the water pump

For optimum performance, Perkins recommends a

Coolant Recommendations

1:1 mixture of a water/glycol solution.

• ELC

Extended Life Coolant

Note: Use a mixture that will provide protection

against the lowest ambient temperature.

• SCA

Supplement Coolant Additive

Note: 100 percent pure glycol will freeze at a

• ASTM

American Society for Testing and

temperature of -13 °C (8.6 °F).

Materials

Most conventional antifreezes use ethylene glycol.

ELC - extended life coolant. A coolant that relies on

organic inhibitors for corrosion and cavitation

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

protection. Also called OAT coolant (Organic Acid

with water, ethylene and propylene glycol provide

Technology).

similar protection against freezing and boiling. Refer

to Table 6 and refer to table 7 .

SCA - supplemental coolant additive, concentrated

Table 6

inorganic inhibitor package.

Ethylene Glycol

Extender - concentrated organic inhibitor package.

Concentration

Freeze Protection

Conventional Coolant - a coolant that relies on

50 Percent

-36 °C (-33 °F)

inorganic inhibitors for corrosion and cavitation

protection.

60 Percent

-51 °C (-60 °F)

Hybrid Coolant - a coolant in which the corrosion and

cavitation protection is based on a mixture of organic

NOTICE

and inorganic inhibitors.

Do not use propylene glycol in concentrations that

exceed 50 percent glycol because of the reduced

The following coolants are recommended for used in

heat transfer capability of propylene glycol. Use ethyl-

Perkins diesel engines:

ene glycol in conditions that require additional protec-

tion against boiling or freezing.

Preferred - Perkins ELC

Table 7

Acceptable - A commercial heavy-duty antifreeze

Propylene Glycol

that meets “ASTM D6210” or “ASTM D4985”

specifications.

Concentration

Freeze Protection

50 Percent

-29 °C (-20 °F)

NOTICE

The Perkins industrial engines with a NOx reduc-

tion system must be operated with a minimum

To check the concentration of glycol in the coolant,

30% volume glycol-water mixture, Perkins recom-

measure the specific gravity of the coolant.

mends 50% volume glycol-water mixture of water

and glycol. The 50% concentration allows the

NOx reduction system to operate correctly at

high ambient temperatures.

M0076814-03

Maintenance Section

Fluid Recommendations

Containers of several sizes are available. Consult

NOTICE

your Perkins distributor for the part numbers.

Do not use a commercial coolant/antifreeze that only

meets the ASTM D3306 specification. This type of

coolant/antifreeze is made for light automotive

ELC Cooling System Maintenance

applications.

Correct additions to the Extended Life

Perkins recommends a 50% mixture of water and

Coolant

glycol. This mixture of water and glycol will provide

optimum heavy-duty performance as an antifreeze.

NOTICE

This ratio may be changed to 40% water to 60%

Use only Perkins products for pre-mixed coolants.

glycol if extra freezing protection is required.

Mixing Extended Life Coolant with other products re-

A mixture of SCA inhibitor and water is acceptable

duces the Extended Life Coolant service life. Failure

but will not give the same level of corrosion, boiling

to follow the recommendations can reduce cooling

and, freezing protection as ELC. Perkins

system components life unless appropriate corrective

recommends a 6 percent to 8 percent concentration

action is performed.

of SCA in those cooling systems. Distilled water or

deionized water is preferred.

To maintain the correct balance between the

Table 8

antifreeze and the additives, you must maintain the

recommended concentration of ELC. Lowering the

Coolant Service Life

proportion of antifreeze lowers the proportion of

Coolant Type

Service Life⁽¹⁾

additive. Lowering the ability of the coolant to protect

the system will form pitting, from cavitation, from

6,000 Service Hours or Three

erosion, and from deposits.

Perkins ELC

Years

Commercial Heavy-Duty Anti-

NOTICE

freeze that meets “ASTM

3000 Service Hours or Two Year

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

D6210”

system that is filled with Extended Life Coolant

(ELC).

Commercial SCA inhibitor and

3000 Service Hours or One Year

Water

Do not use supplemental coolant additive (SCA).

⁽¹⁾ Use the interval that occurs first. The cooling system must also

be flushed out at this time.

ELC Cooling System Cleaning

Perkins ELC

Note: If the cooling system is already using ELC,

Perkins provides ELC for use in the following

cleaning agents are not required to be used at the

applications:

specified coolant change interval. Cleaning agents

are only required if the system has been

• Heavy-duty spark ignited gas engines

contaminated by the addition of some other type of

coolant or by cooling system damage.

• Heavy-duty diesel engines

Clean water is the only cleaning agent that is

• Automotive applications

required when ELC is drained from the cooling

system.

The anti-corrosion package for ELC is different from

the anti-corrosion package for other coolants. ELC is

Before the cooling system is filled, the heater control

an ethylene glycol base coolant. However, ELC

(if equipped) must be set to the HOT position. Refer

contains organic corrosion inhibitors and antifoam

to the OEM to set the heater control. After the cooling

agents with low amounts of nitrite. Perkins ELC has

system is drained and the cooling system is refilled,

been formulated with the correct amount of these

operate the engine until the coolant level reaches the

additives to provide superior corrosion protection for

normal operating temperature and until the coolant

all metals in engine cooling systems.

level stabilizes. As needed, add the coolant mixture

to fill the system to the specified level.

ELC is available in a premixed cooling solution with

distilled water. ELC is a 1:1 mixture. The Premixed

ELC provides freeze protection to -36 °C (-33 °F).

Changing to Perkins ELC

The Premixed ELC is recommended for the initial fill

of the cooling system. The Premixed ELC is also

To change from heavy-duty antifreeze to the Perkins

recommended for topping off the cooling system.

ELC, perform the following steps:

M0076814-03

Maintenance Section

Fluid Recommendations

• Drain the cooling system into a suitable container.

NOTICE

Dispose of the coolant according to local

Care must be taken to ensure that all fluids are con-

tained during performance of inspection, mainte-

regulations. Flush the system with a 5 to 10

nance, testing, adjusting and the repair of the

percent solution of Perkins ELC. Fill the system

product. Be prepared to collect the fluid with suitable

with the Perkins ELC.

containers before opening any compartment or disas-

sembling any component containing fluids.

• Maintain the system as a conventional Heavy-

Duty Coolant. Treat the system with an SCA.

Dispose of all fluids according to local regulations

Change the coolant at the interval that is

and mandates.

recommended for the conventional Heavy-Duty

Coolant.

1. Drain the coolant into a suitable container.

Commercial Heavy-Duty Antifreeze and

2. Dispose of the coolant according to local

SCA

regulations.

3. Fill the cooling system with a 33 percent solution of

NOTICE

Perkins ELC and operate the engine, ensure that

Commercial Heavy-Duty Coolant which contains

Amines as part of the corrosion protection system

the thermostat opens. Stop the engine and allow

must not be used.

the engine to cool. Drain the coolant.

Note: Use distilled or deionized water in the solution.

NOTICE

Never operate an engine without water temperature

4. Again, fill the cooling system with a 33 percent

regulators in the cooling system. Water temperature

solution of Perkins ELC and operate the engine

regulators help to maintain the engine coolant at the

ensure that the thermostat opens. Stop the engine

correct operating temperature. Cooling system prob-

and allow to cool.

lems can develop without water temperature

regulators.

5. Drain the cooling system.

Check the glycol concentration to ensure adequate

NOTICE

protection against boiling or freezing. Perkins

Incorrect or incomplete flushing of the cooling system

recommends the use of a refractometer for checking

can result in damage to copper and other metal

the glycol concentration. A hydrometer should not be

components.

used.

Perkins engine cooling systems should be tested at

500 hour intervals for the concentration of SCA.

NOTICE

Most commercial cooling system cleaning agents are

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

corrosive and their use is not recommended by

An SCA that is liquid may be needed at 500 hour

Perkins.

intervals.

6. Fill the cooling system with the Perkins Premixed

NOTICE

Do not mix types and brands of coolant.

ELC. Operate the engine. Ensure that all coolant

valves open then stop the engine. When cool

Do not mix brands and types of SCAs.

check the coolant level.

Do not mix SCAs and Extenders.

ELC Cooling System Contamination

Only use SCAs or Extender approved by coolant

manufacturer and compatible with coolant.

NOTICE

Mixing ELC with other products reduces the effective-

ness of the ELC and shortens the ELC service life.

Adding the SCA to Heavy-Duty Coolant

Failure to follow these recommendations can result in

shortened cooling system component life.

at the Initial Fill

ELC cooling systems can withstand contamination to

Coolants conforming to ASTM D4985 and not

a maximum of 10 percent of conventional heavy-duty

conforming D6210 require the addition of SCA at

antifreeze or SCA. If the contamination exceeds 10

initial fill.

percent of the total system capacity, perform ONE of

Use the equation that is in Table 9 to determine the

the following procedures:

amount of SCA that is required when the cooling

system is initially filled.

M0076814-03

Maintenance Section

Fluid Recommendations

Table 9

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

Cleaning the System of Heavy-Duty

The Initial Fill

Antifreeze

V × 0.07 = X

V is the total volume of the cooling system.

Note: Before corrosion inhibitors can be effective the

cooling system must be free from rust, scale and

X is the amount of SCA that is required.

deposits.

• Drain the cooling system.

Table 10 is an example for using the equation that is

in Table 9 .

• Before filling the cooling system with acceptable

Table 10

quality water, pre-dissolve the cleaning agent in

Example Of The Equation For Adding The SCA To The Heavy-

the water. Use a non-foaming detergent to clean

Duty Coolant At The Initial Fill

oil contamination, consult your Perkins dealer for

suitable product.

Total Volume of the

Multiplication

Amount of SCA

Cooling System (V)

Factor

that is Required

(X)

NOTICE

Most commercial cooling system cleaning agents are

15 L (4 US gal)

× 0.07

1.05 L (35.5 oz)

corrosive and their use is not recommended by

Perkins.

Adding The SCA to The Heavy-Duty

The cooling system must be thoroughly flushed with

clean water after using cleaning agents.

Coolant For Maintenance

Cleaning agents for marine or industrial cooling sys-

Heavy-duty antifreeze of all types REQUIRE periodic

tem must not be used, these areveryaggressiveand

additions of an SCA.

can cause damage to cooling system components.

Test the antifreeze periodically for the concentration

of SCA. For the interval, refer to the Operation and

Maintenance Manual, “Maintenance Interval

• Run the engine for approximately 30 minutes and

Schedule” (Maintenance Section). Cooling System

then leave the engine to cool down.

Supplemental Coolant Additive (SCA) Test/Add.

• Take a sample of the solution from the cooling

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

system, drain the system.

The size of the cooling system determines the

amount of SCA that is needed.

• Allow the sample to sit for at least 30 minutes and

check for signs of oil and deposits. If oil and

Use the equation that is in Table 11 to determine the

deposits are still present repeat the procedure.

amount of SCA that is required, if necessary:

Table 11

• Flush the system with clean water.

Equation For Adding The SCA To The Heavy-Duty Coolant

• Fill the system with new coolant.

For Maintenance

V × 0.023 = X

i08273319

V is the total volume of the cooling system.

Fluid Recommendations

X is the amount of SCA that is required.

Table 12 is an example for using the equation that is

in Table 11 .

General Lubricant Information

Table 12

Because of government regulations regarding the

Example Of The Equation For Adding The SCA To The Heavy-

certification of exhaust emissions from the engine,

Duty Coolant For Maintenance

the lubricant recommendations must be followed.

Total Volume of the

Multiplication

Amount of SCA

• API

American Petroleum Institute

Cooling System (V)

Factor

that is Required

(X)

• SAE

Society Of Automotive Engineers Inc.

15 L (4 US gal)

× 0.023

0.35 L (11.7 oz)

• ACEA

Association des Constructers

European Automobiles.

• ECF-3

Engine Crankcase Fluid

M0076814-03

Maintenance Section

Fluid Recommendations

Licensing

NOTICE

Perkins require the use of the following specifica-

The Engine Oil Licensing and Certification System by

tion of engine oil. Failure to use the appropriate

the American Petroleum Institute (API) and the

specification of engine oil will reduce the life of

Association des Constructers European Automobiles

your engine. Failure to use the appropriate speci-

and (ACRA) is recognized by Perkins. For detailed

fication of engine oil will also reduce the life of

information about this system, see the latest edition

your aftertreatment system.

of the “API publication No. 1509”. Engine oils that

bear the API symbol are authorized by API.

Table 13

Oil Specification

API CK-4

ACEA E9

ECF-3

API CK-4 and ACEA E9 oil categories have the

following chemical limits:

•

0.1 percent maximum sulfated ash

•

0.12 percent maximum phosphorous

•

0. 4 percent maximum sulfur

The chemical limits were developed to maintain the

Illustration 56

g06183768

expected life of the engine aftertreatment system.

Typical API symbol

The performance of the engine aftertreatment system

can be adversely affected if oil that is not specified in

Terminology

table 13 is used.

The life of your Aftertreatment system is defined by

Certain abbreviations follow the nomenclature of

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

the accumulation of ash on the surface of the filter.

Ash is the inert part of the particulate matter. The

abbreviations, and some classifications follow the

“EMA Recommended Guideline on Diesel Engine

system is designed to collect this particulate matter.

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

There is a small percentage of particulate matter that

definitions that will be of assistance in purchasing

is left behind as the soot is burnt. This matter will

lubricants.

eventually block the filter, causing loss of

performance and increased fuel consumption. Most

Refer to Perkins Diesel Engines Fluids

of the ash comes from the engine oil which is

Recommendations, M0113102 for additional

gradually consumed during normal operation. This

information that relates to oil.

ash is passes through the exhaust. To meet the

designed life of the product, the use of the

Engine Oil

appropriate engine oil is essential. The oil

specification that is listed in table 13 has low ash

content.

Commercial Oils

Maintenance intervals for engines that use

Perkins recommends use of Perkins Diesel Engine

biodiesel - The oil change interval can be adversely

Oil for all Perkins engines. Perkins unique oil

affected by the use of biodiesel. Use oil analysis to

formulations have been developed to provide full

monitor the condition of the engine oil. Use oil

performance and maximum service life of your

analysis also to determine the oil change interval that

engine, and in tests have been shown to provide

is optimum.

superior protection. Available in suitable API

classifications to meet the emissions requirements

and performance of your engine, Refer to 13 for the

Note: API FA-4 oil is designed for use in selected

correct oil specification for your engine. Consult your

on-highway applications and is NOT designed to

Perkins distributor for more information on these

support off-road applications, including Perkins

multi-grade oils.

Engines. DO NOT use API FA-4 oil for Perkins

engines. These engine oils are not approved by

Perkins and these engine oils must not be used:

CC, CD, CD-2, CF-4, CG-4, CH-4, and CI-4.

M0076814-03

Maintenance Section

Fluid Recommendations

Lubricant Viscosity Recommendations

Aftermarket Oil Additives

for Direct Injection (DI) Diesel Engines

Perkins does not recommend the use of aftermarket

additives in oil. Aftermarket additives are not

The correct SAE viscosity grade of oil is determined

necessary to achieve the engines maximum service

by the minimum ambient temperature during cold

life or rated performance. Fully formulated, finished

engine start-up, and the maximum ambient

oils consist of base oils and of commercial additive

temperature during engine operation.

packages. These additive packages are blended into

the base oils at precise percentages to help provide

Refer to illustration 57 (minimum temperature) to

finished oils with performance characteristics that

determine the required oil viscosity for starting a cold

meet industry standards.

engine.

There are no industry standard tests that evaluate

Refer to illustration 57 (maximum temperature) to

the performance or the compatibility of aftermarket

select the oil viscosity for engine operation at the

additives in finished oil. Aftermarket additives may

highest ambient temperature that is anticipated.

not be compatible with the finished oils additive

package, which could lower the performance of the

Generally, use the highest oil viscosity that is

finished oil. The aftermarket additive could fail to mix

available to meet the requirement for the temperature

with the finished oil. This failure could produce sludge

at start-up.

in the crankcase. Perkins discourages the use of

aftermarket additives in finished oils.

To achieve the best performance from a Perkins

engine, conform to the following guidelines:

• See the appropriate “Lubricant Viscosities” . Refer

to the illustration 57 to find the correct oil viscosity

grade for your engine.

• 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”.

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.

Illustration 57

g03329707

Lubricant Viscosities

The oil analysis is a diagnostic tool that is used to

Supplemental heat is recommended for cold soaked

determine oil performance and component wear

starts below the minimum ambient temperature.

rates. Contamination can be identified and measured

by using oil analysis. The oil analysis includes the

Supplemental heat may be required for cold soaked

following tests:

starts that are above the minimum temperature that

is stated, depending on the parasitic load and other

• The Wear Rate Analysis monitors the wear of the

factors. Cold soaked starts occur when the engine

engines metals. The amount of wear metal and

has not been operated for a period of time. This

interval will allow the oil to become more viscous due

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

to cooler ambient temperatures.

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.

M0076814-03

Maintenance Section

Refill Capacities and Recommendations

• The Oil Condition Analysis determines the loss of

the oils 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.

Illustration 60

g02300474

Deep pan

i06937316

The refill capacities for the engine crankcase reflect

Refill Capacities and

the approximate capacity of the crankcase or sump

plus standard oil filters. Auxiliary oil filter systems will

Recommendations

require extra oil. Refer to the OEM specifications for

the capacity of the auxiliary oil filter.

Table 14

Refill Capacities

2000 Series Industrial Engines

Approximate Refill Capacities

Lubricant Refill Capacity

Engine with 1

Engine with 2

Oil Sump⁽¹⁾

Filter

Filters

Standard pan

34 L (36 qt)

43 L (45 qt)

Center pan

60 L (63 qt)

62 L (66 qt)

Deep pan

68 L (72 qt)

70 L (74 qt)

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

sump which include the standard oil filters that are installed at

the factory. Engines with auxiliary oil filters will require extra oil.

Refer to the OEM specifications for the capacity of the auxiliary

oil filter.

Coolant Refill Capacity

To maintain the cooling system, the total cooling

system capacity must be known. The capacity of the

total cooling system will vary. The capacity will

Illustration 58

g02300456

depend on the size of the radiator (capacity). Table

Standard pan

15 should be completed by the customer for the

maintenance of the cooling system.

Table 15

Approximate Capacity of the Cooling System

Compartment or

Liters

Quarts

System

Total Cooling System

(1)

Illustration 59

g02300473

⁽¹⁾ The total cooling system capacity includes the following compo-

nents: The engine block, the radiator, and all coolant hoses and

Center pan

lines.

Recommendation

Refer to this Operation and Maintenance Manual,

“Fluid Recommendations” for information about the

fluids which are acceptable for this engine.

M0076814-03

Maintenance Section

Maintenance Recommendations

Do not loosen the high-pressure fuel lines to remove

Maintenance

air pressure from the fuel system.

Recommendations

Engine Oil

i08186078

To relieve pressure from the lubricating system, turn

System Pressure Release

off the engine.

i07915408

Coolant System

Welding on Engines with

Electronic Controls

Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-

NOTICE

diator is cool. Then loosen cap slowly to relieve

Because the strength of the frame may decrease,

the pressure.

some manufacturers do not recommend welding onto

a chassis frame or rail. Consult the OEM of the equip-

To relieve the pressure from the coolant system, turn

ment or your Perkins dealer regarding welding on a

off the engine. Allow the cooling system pressure cap

chassis frame or rail.

to cool. Remove the cooling system pressure cap

slowly to relieve pressure.

Correct welding procedures are necessary to avoid

damage to the engines ECM, sensors, and

associated components. When possible, remove the

Fuel System

component from the unit and then weld the

component. If removal of the component is not

To relieve the pressure from the fuel system, turn off

possible, the following procedure must be followed

the engine.

when you weld on a unit equipped with an Electronic

Engine. The following procedure is considered to be

High-Pressure Fuel Lines (If Equipped)

the safest procedure to weld on a component. This

procedure should provide a minimum risk of damage

to electronic components.

NOTICE

Contact with high pressure fuel may cause fluid

Do not ground the welder to electrical components

penetration and burn hazards. High pressure fuel

such as the ECM or sensors. Improper grounding

spray may cause a fire hazard. Failure to follow

can cause damage to the drive train bearings, hy-

these inspection, maintenance and service in-

draulic components, electrical components, and oth-

structions may cause personal injury or death.

er components.

The high-pressure fuel lines are between the high-

Clamp the ground cable from the welder to the com-

pressure fuel pump and the high-pressure fuel

ponent that will be welded. Place the clamp as close

manifold. The high-pressure fuel lines are also

as possible to the weld. This will help reduce the pos-

between the fuel manifold and cylinder head. These

sibility of damage.

fuel lines are different from fuel lines on other fuel

systems.

Note: Perform the welding in areas that are free from

The following are the differences:

explosive hazards.

• The high-pressure fuel lines are constantly

1. Stop the engine. Turn the switched power to the

charged with high pressure.

OFF position.

• The internal pressures of the high-pressure fuel

2. Ensure that the fuel supply to the engine is turned

lines are higher than other types of fuel system.

off.

Before any service or repair is performed on the

3. Disconnect the negative battery cable from the

engine fuel lines, perform the following tasks:

battery. If a battery disconnect switch is provided,

1. Stop the engine.

open the switch.

2. Wait for 10 minutes.

4. Disconnect all electronic components from the

wiring harnesses. Include the following

components:

M0076814-03

Maintenance Section

Severe Service Application

• Electronic components for the driven

5. Connect the welding ground cable directly to the

equipment

part that will be welded. Place the ground cable as

close as possible to the weld to reduce the

• ECM

possibility of welding current damage to the

following components. Bearings, hydraulic

• Sensors

components, electrical components, and ground

straps.

• Electric operated fuel pump

Note: If electrical/electronic components are used as

• Electronically controlled valves

a ground for the welder, or electrical/electronic

components are located between the welder ground

• Relays

and the weld, current flow from the welder could

• Aftertreatment ID module

severely damage the component.

6. Protect the wiring harness from welding debris and

NOTICE

spatter.

Do not use electrical components (ECM or ECM sen-

sors) or electronic component grounding points for

7. Use standard welding practices to weld the

grounding the welder.

materials.

i07014325

Severe Service Application

Severe service is the application of an engine that

either exceeds the current published standards for

that engine range. Or results in the engine being

used at the extremes of certain operating conditions.

• Performance such as power range, speed range,

and fuel consumption

• Fuel quality

• Operational Altitude

• Maintenance intervals

• Oil selection and maintenance

• Coolant type and maintenance

Illustration 61

g06477753

• Environmental qualities

Use the example above. The current flow from the

welder to the ground clamp of the welder will not

• Installation

damage any associated components.

• The temperature of the fluid in the engine

(1) Engine

(2) Welding electrode

Refer to the standards for the engine or consult your

(3) Keyswitch in the OFF position

(4) Battery disconnect switch in the open position

Perkins distributor to determine if the engine is

(5) Disconnected battery cables

operating within the defined parameters.

(6) Battery

(7) Electrical/Electronic component

Severe service operation can accelerate component

(8) The component that is being welded

wear. Engines that operate under severe conditions

(9) Current path of the welder

may need more frequent maintenance intervals to

(10) Ground clamp for the welder

ensure maximum reliability and retention of full

service life.

M0076814-03

Maintenance Section

Severe Service Application

Due to individual applications, identification is not

possible for all the factors which can contribute to

severe service operation. Consult your Perkins

distributor for the unique maintenance that is

necessary for the engine.

The operating environment, incorrect operating

procedures, and incorrect maintenance procedures

can be factors which contribute to a severe service

application.

Environmental Factors

Ambient temperatures - The engine may be

exposed to extended operation in extremely cold

environments or hot environments. Valve

components can be damaged by carbon buildup if

the engine is frequently started and stopped in very

cold temperatures. Extremely hot intake air reduces

engine performance.

Quality of the air - The engine may be exposed to

extended operation in an environment that is dirty or

dusty, unless the equipment is cleaned regularly.

Mud, dirt, and dust can encase components.

Maintenance can be very difficult. The buildup can

contain corrosive chemicals.

Buildup - Compounds, elements, corrosive

chemicals, and salt can damage some components.

Altitude - Problems can arise when the engine is

operated at altitudes that are higher than the

intended settings for that application. Necessary

adjustments should be made.

Incorrect Operating Procedures

• Extended operation at low idle

• Frequent hot shutdowns

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application

Incorrect Maintenance Procedures

• Extending the maintenance intervals

• Failure to use recommended fuel, lubricants, and

coolant/antifreeze

M0076814-03

Maintenance Section

Maintenance Interval Schedule

i07509666

“ Belts - Inspect/Replace”

“ Cooling System Supplemental Coolant Additive

Maintenance Interval Schedule

(SCA) - Test/Add”

“ Engine Oil and Filter - Change”

When Required

“ Fuel System Primary Filter (Water Separator)

Element - Replace”

104

“ Battery - Recycle”

“ Fuel System Secondary Filter - Replace”

105

“ Battery - Replace”

“ Hoses and Clamps - Inspect/Replace”

107

“ Battery or Battery Cable - Disconnect”

Every 500 Service Hours or 3

“DEF Filler Screen (Emission Related Component) -

Clean”

Months

“Diesel Exhaust Fluid (Emission Related Component)

“ Belts - Inspect/Adjust/Replace”

- Fill”

“ Engine - Clean”

Every 2500 Service Hours

“ Engine Air Cleaner Element - Replace”

“ Engine Valve Lash - Check”

103

“ Engine Storage Procedure - Check”

100

Every 3000 Service Hours or 3

“ Fuel System - Prime”

103

Years

“ Fuel Tank Water and Sediment - Drain”

106

“ Cooling System Coolant (DEAC) - Change”

“ Radiator - Clean”

Every 4000 Service Hours

Daily

“ Air Compressor - Check”

“ Air Tank Moisture and Sediment - Drain”

“ Engine Mounts - Inspect”

“ Cooling System Coolant Level - Check”

“ Starting Motor - Inspect”

109

“ Driven Equipment - Check”

Every 5000 Service Hours

“ Engine Air Cleaner Service Indicator - Inspect”. . 96

“ Engine Oil Level - Check”

“ARD Spark Plug (Emission Related Component) -

Clean”

“ Fuel System Primary Filter/Water Separator -

“Diesel Exhaust Fluid Filter (Emission Related

Drain”

105

Component) - Replace”

“ Power Take-Off Clutch - Check”

108

“Diesel Particulate Filter (Emission Related

“Walk-Around Inspection”

110

Component) - Clean”

Every 250 Service Hours

“ Engine Oil Sample - Obtain”

“Grounding Stud - Inspect/Clean/Tighten”

107

Initial 500 Service Hours

“ Engine Valve Lash - Check”

103

Every 500 Service Hours

“ Battery Electrolyte Level - Check”

M0076814-03

Maintenance Section

ARD Spark Plug (Emission Related Component) - Clean

i07508570

2. Debris may have collected in the spark plug well.

Thoroughly remove any debris. Use compressed

ARD Spark Plug (Emission

air. The maximum air pressure for cleaning

purposes must be below 205 kPa (30 psi). Ensure

Related Component) - Clean

that the area around the spark plug is clean and

free of dirt and debris.

3. Use a 22 mm (0.86 inch)22mm spark plug socket

and a breaker bar to loosen the spark plug. After

Personal injury can result from air pressure.

the spark plug has been loosened, use the spark

plug socket to remove the spark plug by hand to

Personal injury can result without following prop-

detect problems with the threads. After the spark

er procedure. When using pressure air, wear a

plug has been removed, inspect the used spark

protective face shield and protective clothing.

plug and the gasket.

The maximum air pressure for cleaning purposes

4. After removing the spark plug, clean the ground

must be reduced to 205 kPa (30 psi) when the air

probe inside the ARD combustion head by running

nozzle is deadheaded.

a T400005 Plug Bore Brush through the hole in

the ARD combustion head. This tool scrapes

NOTICE

debris from the seat and from the threads. Run the

If the engine is running or the key is in the ON posi-

brush through the hole several times.

tion the Aftertreatment Regeneration Device (ARD)

plug will continue to fire. Turn the key to the OFF po-

Note: The spark plug may be damaged if the spark

sition before servicing the ARD plug.

plug is dropped. Do not install a spark plug that has

been dropped or a spark plug that is damaged.

5. Carefully clean the spark plug using a nonmetallic

Removing the Spark Plug

cleaning pad. If the probe appears to be bent,

replace the spark plug. Do not use a thread tap. A

thread tap will remove metal unnecessarily. The

threads could be stripped and the combustion

group could be damaged.

Installing the Spark Plug

Note: Do not use anti-seize compound on the spark

plug. Most of the heat is transferred through the

threads and the seat area of the spark plug. Contact

of the metal surfaces must be maintained to provide

the heat transfer that is required.

1. Ensure that the spark plug is clean and free of dirt

and oil.

NOTICE

Do not overtighten the spark plug. The shell can be

cracked and the gasket can be deformed. The metal

can deform and the gasket can be damaged. The

shell can be stretched. This will loosen the seal that

is between the shell and the insulator, allowing com-

Illustration 62

g06046854

bustion pressure to blow past the seal. Serious dam-

Typical example

age to the engine can occur.

(1) Spark plug

Use the proper torque.

(2) Wiring harness

1. Remove wire harness (2) from spark plug (1).

2. Install the spark plug (1) by hand until the spark

plug contacts the ARD. Tighten the spark plug to a

torque of 47 N·m (34 lb ft)

M0076814-03

Maintenance Section

Air Compressor - Check

3. Connect the wiring harness (2.

The function of the pressure relief valve is to bypass

air when there is a malfunction in the system for the

air compressor.

i06111571

The pressure relief valve for the air compressor

Air Compressor - Check

releases air at 1723 kPa (250 psi). If the pressure

relief valve for the air compressor exhausts, all

(If Equipped)

personnel should be at a safe distance away from the

air compressor. All personnel should also stay clear

of the air compressor when the engine is operating

and the air compressor is exposed.

Consult your Perkins distributor for assistance.

Do not disconnect the air line from the air com-

pressor governor without purging the air brake

and the auxiliary air systems. Failure to purge the

i00847451

air brake and the auxiliary air systems before re-

moving the air compressor and/or the air lines

Air Tank Moisture and

could cause personal injury.

Sediment - Drain

(If Equipped)

Moisture and sediment in the air starting system can

cause the following conditions:

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

When opening the drain valve, wear protective

gloves, a protective face shield, protective cloth-

ing, and protective shoes. Pressurized air could

cause debris to be blown and result in personal

injury.

1. Open the drain valve that is on the bottom of the

Illustration 63

g03813903

air tank. Allow the moisture and sediment to drain.

Typical example

2. Close the drain valve.

(1) Pressure relief valve

3. Check the air supply pressure. The air starting

motor requires a minimum of 620 kPa (90 psi) of

air pressure to operate properly. The maximum air

If the air compressor pressure relief valve that is

pressure must not exceed 1550 kPa (225 psi).

mounted in the air compressor cylinder head is

The normal air pressure will be 758 to 965 kPa

bypassing compressed air, there is a malfunction

(110 to 140 psi).

in the air system, possibly ice blockage. Under

these conditions, your engine may have insuffi-

i08232552

cient air for normal brake operation.

Do not operate the engine until the reason for the

Battery - Recycle

air bypass is identified and corrected. Failure to

heed this warning could lead to property damage,

personal injury, or death to the operator or

Always recycle a battery. Never discard a battery.

bystanders.

Return used batteries to one of the following

locations:

• Abatterysupplier

M0076814-03

Maintenance Section

Battery - Replace

• An authorized battery collection facility

7. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.

• A recycling facility

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

i01878164

on the starter motor to the NEGATIVE “-” battery

terminal.

Battery - Replace

i02747977

Battery Electrolyte Level -

Check

Batteries give off combustible gases which can

explode. A spark can cause the combustible

gases to ignite. This can result in severe personal

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

injury or death.

when the engine is run for short periods, the batteries

may not fully recharge. Ensure a full charge in order

Ensure proper ventilation for batteries that are in

to help prevent the battery from freezing. If batteries

an enclosure. Follow the proper procedures in or-

are correctly charged, the ammeter reading should

der to help prevent electrical arcs and/or sparks

be very near zero, when the engine is in operation.

near batteries. Do not smoke when batteries are

serviced.

All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a

face shield and protective clothing when working

The battery cables or the batteries should not be

on or near batteries.

removed with the battery cover in place. The bat-

tery cover should be removed before any servic-

ing is attempted.

1. Remove the filler caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion

If the addition of water is necessary, use distilled

resulting in personal injury.

water. If distilled water is not available use clean

water that is low in minerals. Do not use artificially

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

softened water.

electrical loads.

2. Check the condition of the electrolyte with a

2. Turn off any battery chargers. Disconnect any

suitable battery tester.

battery chargers.

3. Install the caps.

3. The NEGATIVE “-” cable connects the NEGATIVE

4. Keep the batteries clean.

“-” battery terminal to the NEGATIVE “-” terminal

on the starter motor. Disconnect the cable from the

Clean the battery case with one of the following

NEGATIVE “-” battery terminal.

cleaning solutions:

4. The POSITIVE “+” cable connects the POSITIVE

• Use a solution of 0.1 kg (0.2 lb) baking soda

“+” battery terminal to the POSITIVE “+” terminal

and 1 L (1 qt) of clean water.

on the starting motor. Disconnect the cable from

the POSITIVE “+” battery terminal.

• Use a solution of ammonium hydroxide.

Note: Always recycle a battery. Never discard a

Thoroughly rinse the battery case with clean

battery. Return used batteries to an appropriate

water.

recycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure that

the engine start switch is OFF.

M0076814-03

Maintenance Section

Battery or Battery Cable - Disconnect

i05424317

i06940875

Battery or Battery Cable -

Belts - Inspect/Adjust/Replace

Disconnect

(Vee Belt General Information)

The information within this section may be used as a

guide to adjust the tension of the belt. If the Original

Equipment Manufacture (OEM has installed the belt

The battery cables or the batteries should not be

system, then refer to OEM information.

removed with the battery cover in place. The bat-

tery cover should be removed before any servic-

Ensure that the engine cannot start when servicing or

ing is attempted.

repairs are performed.

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion

Alternator Belt and Fan Belt

resulting in personal injury.

Inspect

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

Slippage of loose belts can reduce the efficiency of

ignition switch (if equipped) to the OFF position

the driven components. Vibration of loose belts can

and remove the key and all electrical loads.

cause unnecessary wear on the following

components:

Note: After the engine has stopped, allow 2 minutes

in order for the diesel exhaust fluid lines to be purged

• Belts

before disconnecting the power.

• Pulleys

2. Disconnect the negative battery terminal. Ensure

that the cable cannot contact the terminal. When

• Bearings

four 12 V batteries are involved, 2 negative

If the belts are too tight, unnecessary stress is placed

connections must be disconnected.

on the components and reduces the service life of the

components.

3. Remove the positive connection.

To maximize the engine performance, inspect the

4. Clean all disconnected connection and battery

belts for wear splitting and for cracking. Replace belts

terminals.

that are worn or damaged

5. Use a fine grade of sandpaper to clean the

Adjust

terminals and the cable clamps. Clean the items

until the surfaces are bright or shiny. DO NOT

The section shows two different types of adjuster

remove material excessively. Excessive removal

used to adjust the alternator belt tension.

of material can cause the clamps to fit incorrectly.

Coat the clamps and the terminals with a suitable

silicone lubricant or petroleum jelly.

6. Tape the cable connections in order to help

prevent accidental starting.

7. Proceed with necessary system repairs.

8. In order to connect the battery, connect the

positive connection before the negative connector.

M0076814-03

Maintenance Section

Vee Belt General Information

Link adjuster

Rod adjuster

Illustration 64

g06108813

Illustration 65

g06109400

Typical example

1. Remove guards, refer to the OEM for the correct

1. Remove the belt guard, refer to OEM for the

procedure.

correct procedure.

2. Loosen nut and bolt (2) and loosen nut and bolt

2. Loosen nut and bolt (1) and loosen bolt (3).

(3).

3. Loosen one of the nuts (4). Adjusting nuts (4) will

3. Adjust alternator (1) to obtain the correct tension

move the alternator (2).

on the belt. Use a suitable belt tension tool to set

4. Adjust nuts (4) for the correct tension on the belt.

the belt tension.

Use a suitable belt tension tool to set the belt

4. Tighten nut and bolt (2) and tighten nut and bolt

tension.

(3).

5. With the correct tension set, tighten nut and bolt

5. Tighten nut and bolt (2) to a torque of 47 N·m

(1) and tighten bolt (3).

(34 lb ft). Tighten nut and bolt (3) to a torque of

6. Tighten nut and bolt (1) to a torque of 105 N·m

70 N·m (51 lb ft).

(77 lb ft).

7. Tighten bolt (3) to a torque of 105 N·m (77 lb ft).

8. Tighten nuts (4) to a torque of 105 N·m (77 lb ft).

9. Reinstall the belt guard, refer to OEM for the

correct procedure.

If new drive belts are installed, check the drive belt

tension again after 30 minutes of engine operation

at the rated rpm.

M0076814-03

Maintenance Section

Belts - Inspect/Replace

Fan Belt Adjustment

To replace the fan belts, refer to Disassembly and

Assembly, V-Belts- Remove and Install.

Belt Tension

Table 16

Alternator and Fan Belt Tension

Belt Type

Belt Size

New Belt

Used Belt

Reset Belt

Tension

with fewer

than 10

Hours in

Operation

Alternator

10 mm

645 ± 44

512 ± 44

311 ± 44

belt

(0.39370

inch)

(145 ± 10

(115 ± 10.

(70 ± 10

lb)

Fan Belt

5V/5VX

801 ± 44

645 ± 44

378 ± 44

15 mm

(0.59055

(180 ± 10

(145 ± 10

(85 ± 10

inch)

lb)

Note: Do not set the belt tension when the belts are

Illustration 66

g06109234

hot.

Typical example

i06942621

1. Remove the belt guard, refer to OEM for the

correct procedure.

Belts - Inspect/Replace

2. Loosen lock nut (3). Rotating nut (4) counter-

(General Information for Poly

clockwise will move pulley (1) and loosen belts (2).

Rotating nut (4) clockwise will move pulley (1) and

Vee Belts)

tighten belts (2).

3. With the correct tension set, tighten nut (3).

The polly vee belt may also be called the micro rib

Tighten nut (3) to a torque of 102 N·m (75 lb ft).

belt.

4. Use a suitable belt tension tool to set the belt

tension.

5. Reinstall the belt guard, refer to OEM for the

correct procedure.

If new drive belts are installed, check the drive belt

tension again after 30 minutes of engine operation

at the rated rpm.

Replace

For applications that require multiple drive belts,

replace the drive belts in matched sets. Replacing

one drive belt of a matched set will cause the new

drive belt to carry more load because the older drive

belts are stretched. The additional load on the new

drive belt could cause the new drive belt to fail.

To replace the alternator belt, refer to Disassembly

and Assembly, Alternator Belt - Remove and Install.

M0076814-03

Maintenance Section

Cooling System Coolant (DEAC) - Change

To maximize the engine performance, inspect the

belt for wear and for cracking. Replace the belt if the

belt is worn or damaged.

• Inspect the belt for cracks, splits, glazing, grease,

displacement of the cord and evidence of fluid

contamination.

The belt must be replaced if the following conditions

are present.

• The belt has a crack in more than one rib.

• More than one section of the belt is displaced in

one rib of a maximum length of 50.8 mm (2 inch)

Replace

1. Before the belt has been removed, ensure that rout

of the belt from crankshaft across and around the

other pulley and idlers is understood.

2. The tensioner (5) has a square drive (2) that can

Illustration 67

g06177182

be used to remove the tension from the belt,

Typical example

allowing the belt to be removed.

(1) Polly vee belt

(2) Ribs of the belt

3. When the belt has been removed, ensure that any

idler or pulley that supports the belt is clean and

Inspect

the idler or pulley rotates freely.

For a full description on replacing the belt refer to

Disassembly and Assembly, Alternator Belt -

Remove and Install.

i06606846

Cooling System Coolant

(DEAC) - Change

Clean the cooling system and flush the cooling

system before the recommended maintenance

interval if the following conditions exist:

• The engine overheats frequently.

• Foaming 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: Inspect the water pump and the water

temperature regulator after the cooling system has

been drained.

Illustration 68

g06177194

Typical example

M0076814-03

Maintenance Section

Cooling System Coolant (DEAC) - Change

NOTICE

Fill the cooling system no faster than 19 L (5 US gal)

per minute to avoid air locks.

3. Fill the cooling system with clean water and

operate the engine, ensure that the thermostat

opens. Stop the engine and allow the engine to

cool.

4. Drain the cooling system.

5. Fill the cooling system with clean water and

operate the engine until the engine is warmed to

82 °C (180 °F).

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

the cooling system.

Fill

NOTICE

Fill the cooling system no faster than 19 L (5 US gal)

per minute to avoid air locks.

1. Fill the cooling system with coolant/antifreeze.

Refer to this Operation and Maintenance Manual,

“Fluid Recommendations” topic for more

Illustration 69

g02351659

information on cooling system specifications. Do

The cooling system drain valve is towards the bottom

of the radiator.

not install the cooling system filler cap.

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

Drain

engine rpm to 1500 rpm. Run the engine at high

idle for 1 minute to purge the air from the cavities

of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant level

Pressurized System: Hot coolant can cause seri-

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

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

pipe for filling. Maintain the coolant level within

components are cool. Loosen the cooling system

13 mm (0.5 inch) to the proper level on the sight

pressure cap slowly in order to relieve the

glass.

pressure.

4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If

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

the gasket that is on the cooling system filler cap is

Loosen the cooling system filler cap slowly in

damaged, discard the old filler cap and install a

order to relieve any pressure. Remove the cooling

new filler cap. If the gasket that is on the cooling

system filler cap.

system filler cap is not damaged, perform a

2. Open the cooling system drain valve.

pressure test. The correct pressure for the cooling

system filler cap is stamped on the face of the

Allow the coolant to drain.

cooling system filler cap. If the cooling system filler

cap does not retain the correct pressure, install a

Flush

new cooling system filler cap.

1. Flush the cooling system with clean water in order

to remove any debris.

2. Close the drain valve.

M0076814-03

Maintenance Section

Cooling System Coolant (ELC) - Change

5. Start the engine and inspect the cooling system for

leaks and for proper operating temperature.

i06606848

Cooling System Coolant (ELC

- Change

NOTICE

Perkins ELC must be using with an extender in order

to achieve 12000 hours operation. For more informa-

tion on a suitable extender contact your Perkins

distributor.

Clean the cooling system and flush the cooling

system before the recommended maintenance

interval if the following conditions exist:

• The engine overheats frequently.

• Foaming 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.

Illustration 70

g02351659

Note: When the cooling system is cleaned, only

clean water is needed when the ELC is drained and

Drain

replaced.

Note: Inspect the water pump and the water

temperature regulator after the cooling system has

Pressurized System: Hot coolant can cause seri-

been drained.

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure cap slowly in order to relieve the

pressure.

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

Loosen the cooling system filler cap slowly to

relieve any pressure. Remove the cooling system

filler cap.

2. Open the cooling system drain valve.

Allow the coolant to drain.

Flush

1. Flush the cooling system with clean water to

remove any debris.

2. Close the drain valve.

M0076814-03

Maintenance Section

Cooling System Coolant Extender (ELC) - Add

5. Start the engine and Inspect the cooling system for

NOTICE

leaks and for proper operating temperature.

Fill the cooling system no faster than 19 L (5 US gal)

per minute to avoid air locks.

i06606850

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

Cooling System Coolant

cooling system filler cap.

Extender (ELC) - Add

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

temperature reaches 49 °C to 66 °C

(120 °F to 150 °F).

For Perkins ELC to achieve 12000 hours an extender

must be added at 6000 hours. For a suitable

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

extender, contact your Perkins distributor.

Loosen the cooling system filler cap slowly to

relieve any pressure. Remove the cooling system

i06606851

filler cap. Open the drain valve. Allow the water to

drain. Flush the cooling system with clean water.

Cooling System Coolant Level

Close the drain valve.

- Check

Fill

Check the coolant level when the engine is stopped

NOTICE

and cool.

Fill the cooling system no faster than 19 L (5 US gal)

per minute to avoid air locks.

1. Fill the cooling system with Extended Life Coolant

(ELC). Refer to this Operation and Maintenance

Manual, “Fluid Recommendations” for more

information on cooling system specifications. Do

not install the cooling system filler cap.

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

engine rpm to high idle. Run the engine at high

idle for 1 minute to purge the air from the cavities

of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant level

Illustration 71

g00285520

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

Cooling system filler cap

pipe for filling. Maintain the coolant level within

13 mm (0.5 inch) to the proper level on the sight

glass.

4. Clean the cooling system filler cap. Inspect the

Pressurized System: Hot coolant can cause seri-

gasket that is on the cooling system filler cap. Only

ous burns. To open the cooling system filler cap,

install the used filler cap if the gasket is not

stop the engine and wait until the cooling system

damaged. Test the cap for the correct pressure.

components are cool. Loosen the cooling system

The correct pressure for the cooling system filler

pressure cap slowly in order to relieve the

pressure.

cap is stamped on the face of the cooling system

filler cap. If the cooling system filler cap does not

retain the correct pressure, install a new cooling

1. Remove the cooling system filler cap slowly to

system filler cap.

relieve pressure.

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

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

equipped with a sight glass, maintain the coolant

level to the proper level in the sight glass.

M0076814-03

Maintenance Section

Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Use a Coolant Conditioner Test Kit in order to check

the concentration of the SCA.

Add the SCA, If Necessary

NOTICE

Do not exceed the recommended amount of supple-

mental coolant additive concentration. Excessive

supplemental coolant additive concentration can form

deposits on the higher temperature surfaces of the

cooling system, reducing the engine's heat transfer

characteristics. Reduced heat transfer could cause

cracking of the cylinder head and other high tempera-

ture components. Excessive supplemental coolant

additive concentration could also result in radiator

tube blockage, overheating, and/or accelerated water

Illustration 72

g00103639

pump seal wear. Never use both liquid supplemental

Typical filler cap gaskets

coolant additive and the spin-on element (if

equipped) at the same time. The use of those addi-

3. Clean the cooling system filler cap and check the

tives together could result in supplemental coolant

additive concentration exceeding the recommended

condition of the filler cap gaskets. Replace the

maximum.

cooling system filler cap if the filler cap gaskets are

damaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

Pressurized System: Hot coolant can cause seri-

i03644948

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

Cooling System Supplemental

components are cool. Loosen the cooling system

Coolant Additive (SCA - Test/

pressure cap slowly in order to relieve the

pressure.

Add

NOTICE

When any servicing or repair of the engine cooling

system is performed the procedure must be per-

formed with the engine on level ground. This will al-

Cooling system coolant additive contains alkali.

low you to accurately check the coolant level. This

To help prevent personal injury, avoid contact

will also help in avoiding the risk of introducing an air

with the skin and the eyes. Do not drink cooling

lock into the coolant system.

system coolant additive.

1. Slowly loosen the cooling system filler cap in order

to relieve the pressure. Remove the cooling

Test for SCA Concentration

system filler cap.

Heavy-Duty Coolant/Antifreeze and SCA

Note: Always discard drained fluids according to

local regulations.

NOTICE

2. If necessary, drain some coolant from the cooling

Do not exceed the recommended six percent supple-

mental coolant additive concentration.

system into a suitable container in order to allow

space for the extra SCA.

3. Add the correct amount of SCA. Refer to the

Operation and Maintenance Manual, “Refill

Capacities and Recommendations” for more

information on SCA requirements.

M0076814-03

Maintenance Section

DEF Filler Screen (Emission Related Component) - Clean

4. Clean the cooling system filler cap and inspect the

2. Using a suitable tool, press the tabs (2) in order to

gasket. If the gasket is damaged, discard the old

release the tabs. With the tabs released remove

filler cap and install a new filler cap. If the gasket is

the filter screen (3) from DEF tank neck adapter

not damaged, use a suitable pressurizing pump in

(4).

order to pressure test the filler cap. The correct

3. The filter screen can be cleaned in clean water and

pressure is stamped on the face of the filler cap. If

dried using compressed air. Refer to this

the filler cap does not retain the correct pressure,

Operation and Maintenance Manual, “General

install a new filler cap.

Hazard Information” for information on using

compressed air.

i07508033

4. If the filter screen cannot be cleaned or the filter

DEF Filler Screen (Emission

screen is damaged, then the filter screen must be

replaced.

Related Component) - Clean

5. Install filter screen (3) into DEF tank neck adapter

(4). Press filter screen into neck adapter and

ensure that tabs (2) are located correctly. Install

NOTICE

cap (1).

Ensure that the engine is stopped before any servic-

ing or repair is performed.

i07508564

DEF Manifold Filters (Emission

Related Component) - Replace

NOTICE

Ensure that the engine is stopped before any servic-

ing or repair is performed.

NOTICE

Care must be taken to ensure that Diesel Exhaust

Fluid (DEF) for the system are contained during per-

formance of inspection, maintenance, testing, adjust-

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

the fluid with suitable containers before opening any

compartment or disassembling any component con-

taining fluids.

Dispose of all fluids according to local regulations

and mandates.

Ensure that the area around the DEF manifold is free

from contamination before any servicing or repair is

performed.

There are two different designs of manifold that could

be installed on your application.

Illustration 73

g03725939

Type 1 Manifold

Typical example

1. Remove the manifold, refer to Disassembly and

1. Ensure that the area around cap on the Diesel

Assembly, “Manifold (DEF Heater) - Remove and

Exhaust Fluid (DEF) tank is clean. Remove cap

Install” for the correct procedure.

(1).

M0076814-03

Maintenance Section

DEF Manifold Filters (Emission Related Component) - Replace

Illustration 76

g03806581

Illustration 78

g06159487

1. Note the location of clamp (2). The clamp (2) must

be between the marked location (A).

2. Loosen clamp (2) and remove outer filter (3) from

DEF tank header (1) and discard outer filter (3).

Illustration 77

g03806583

4. Remove the suction filter (4) at the bottom of the

header coils by pulling tabs (5). Replace with a

new suction filter.

5. Install new filter by pulling filter over the manifold

coils up to the bottom of the assembled filter base.

6. Ensure that the band clamp is aligned, as shown in

illustration 77 , to the flat section on the filter base.

Tighten the band clamp to 4.5 ± 0.7 N·m

(40 ± 6 lb in) (1). Ensure that the filter does not

bunch when tightening the band clamp.

7. Install the manifold, refer to Disassembly and

Assembly, “Manifold (DEF Heater) - Remove and

Install” for the correct procedure.

Illustration 79

g06159580

Type 2 Manifold

3. Remove screws (7) and remove retaining plate (6).

To remove the DEF manifold and the hoses

connections from the DEF tank, refer to Disassembly

4. Remove DEF filter (5) from pickup tube (4) and

and Assembly, Manifold (DEF Heater) - Remove and

discard the used filter (5).

Install.

5. Install new filter (5) onto pickup tube (4).

M0076814-03

Maintenance Section

Diesel Exhaust Fluid (Emission Related Component) - Fill

6. Install the retaining plate (6) and install screws (7).

Caution should be used when dispensing DEF near

Tighten screws (7) to a torque of 1.1 N·m

an engine that has recently been running. Spilling

DEF onto hot components may cause the release of

(9.8 lb in).

ammonia vapors. Do not breathe ammonia vapors.

7. Install new outer filter (3) onto DEF tank header

Do not clean up any spills with bleach.

(1). Ensure that the clamp (2) is located between

Ensure that the DEF tank is full before starting work.

the location points (A).

1. Before filling the DEF tank, ensure that the DEF

8. Tighten clamp (2) to a torque of 4.5 N·m (40 lb in).

lines have been purged. Purging of the DEF lines

9. Install the DEF tank header, refer to Disassembly

will take place, after the engine has stopped. Only

and Assembly, Manifold (DEF Heater) - Remove

after purging the DEF lines should the DEF tank

and Install.

be filled. For more information on the time taken

for purging the DEF lines, refer to this Operation

i07508011

and Maintenance Manual, “Battery Disconnect

Switch”.

Diesel Exhaust Fluid

2. Ensure the DEF cap (1) and the surrounding area

(Emission Related

is clean and free from dirt. Ensure that all

Component) - Fill

equipment use in filling the tank is clean and free

from dirt.

3. Remove the DEF cap from the tank.

4. Fill the tank with the required amount of DEF.

Ensure that dirt is not introduced into the tank

during filling. Do not over fill the tank. The DEF will

require room for expansion.

Note: Always fill the DEF tank on level ground. Cold

weather can affect DEF, refer to this Operation, and

Maintenance Manual, “Diesel Exhaust Fluid in cold

Weather” for more information.

5. The opening on the DEF tank (2) is a special

diameter. Ensure that the correct nozzle is used

when filling the DEF tank.

Note: At key on the DEF level gauge will show the

last known DEF level and will transition to the new

DEF level value.

6. Install the DEF cap. Check visually the DEF tank

for leakage.

Illustration 80

g03714036

i07508565

Typical example

Diesel Exhaust Fluid Filter

Ensure that the correct specification Diesel Exhaust

Fluid (DEF) is used. Ensure the cleanliness of the

(Emission Related

DEF, refer to this Operation and Maintenance

Component) - Replace

Manual, “Fluid Recommendations” for more

information.

Care should be taken when dispensing DEF. Spills

• Diesel Exhaust Fluid

(DEF)

should be cleaned immediately. All surfaces should

be wiped clean and rinsed with water.

DEF that has been split will crystallize when the

water within the liquid evaporates. Split DEF will

attack paint and metal. If DEF is split, wash the area

with water.

M0076814-03

Maintenance Section

Diesel Exhaust Fluid Filter (Emission Related Component) - Replace

Illustration 81

g03332612

Illustration 82

g03332637

Typical Example

3. Insert the DEF filter removal tool (4) into the DEF

filter (1) and remove the DEF filter (1).

Personal injury can result from improper han-

dling of chemicals.

Note: Avoid twisting the DEF filter (1) upon removal.

Twisting may cause a tear.

Make sure you use all the necessary protective

equipment required to do the job.

4. Clean the area around the filter housing.

Make sure that you read and understand all direc-

5. Lubricate the seals of the new DEF filter (1) with

tions and hazards described on the labels and

diesel exhaust fluid or distilled water.

material safety data sheet of any chemical that is

used.

6. Install new DEF filter (1) and rubber cone insert.

Observe all safety precautions recommended by

Note: Avoid twisting the DEF filter (1) upon

the chemical manufacturer for handling, storage,

installation. Twisting may cause a tear.

and disposal of chemicals.

7. Install the cap (3). Torque the cap to 20 N·m

(177 lb in).

NOTICE

Ensure that the engine is stopped before any servic-

ing or repair is performed.

1. Remove the DEF filter cap (3) with a 27mm Bi-Hex

socket.

2. Remove the rubber cone insert (2) from the DEF

filter (1).

M0076814-03

Maintenance Section

Diesel Exhaust Fluid Injector (Emission Related Component) - Replace

i07508568

i02151646

Diesel Exhaust Fluid Injector

Driven Equipment - Check

(Emission Related

Component) - Replace

Refer to the OEM specifications for more information

on the following maintenance recommendations for

the driven equipment:

• Inspection

• Adjustment

• Lubrication

• Other maintenance recommendations

Perform any maintenance for the driven equipment

which is recommended by the OEM.

i07819515

Engine - Clean

Personal injury or death can result from high

voltage.

Moisture

can

create

paths

electrical

Illustration 83

g06043006

conductivity.

Typical example

Make sure that the electrical system is OFF. Lock

1. The Diesel Exhaust Fluid (DEF) injector (2) must

out the starting controls and tag the controls “DO

NOT OPERATE” .

be removed from the body of the aftertreatment

regeneration device (1) and a new DEF injector

installed. The DEF lines, coolant lines, and the

NOTICE

electrical connection will need to be removed to

Accumulated grease and oil on an engine is a fire

replace the DEF injector. For more information

hazard. Keep the engine clean. Remove debris and

refer to Disassembly and Assembly, DEF Injector

fluid spills whenever a significant quantity accumu-

and Mounting Remove and Install.

lates on the engine.

Periodic cleaning of the engine is recommended.

i07508573

Steam cleaning the engine will remove accumulated

oil and grease. A clean engine provides the following

Diesel Particulate Filter

benefits:

(Emission Related

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

Consult your Perkins distributor when the diesel

particulate filter needs to be cleaned for the options

• Ease of maintenance

that are available.

The ash monitoring system within the electric control

module will require a reset.

M0076814-03

Maintenance Section

Engine Air Cleaner Element - Replace

Note: Caution must be used to prevent electrical

• Check the pre-cleaner (if equipped) and the dust

components from being damaged by excessive water

bowl daily for accumulation of dirt and debris.

when the engine is cleaned. Pressure washers and

Remove any dirt and debris, as needed.

steam cleaners should not be directed at any

electrical connectors or the junction of cables into the

• Operating in dirty conditions may require more

rear of the connectors. Avoid electrical components

frequent service of the air cleaner element.

such as the alternator, the starter, and the ECM.

Replace the dirty air cleaner elements with new air

Protect the fuel injection pump from fluids to wash the

cleaner elements. Before installation, the air cleaner

engine.

elements should be thoroughly checked for tears

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

Ensure that care is taken that the safety labels,

or the seal of the air cleaner element for damage.

emission label, and all other information labels are

Maintain a supply of suitable air cleaner elements for

not removed during engine cleaning.

replacement purposes.

Aftertreatment

Dual Element Air Cleaner

During the engine cleaning process, ensure that

The dual element air cleaner contains a primary air

water or cleaning fluids cannot enter the

cleaner element and a secondary air cleaner

aftertreatment system. If cleaning fluids enters the

element.

aftertreatment system, damage could occur.

When the engine is operating in environments that

i07003542

are dusty or dirty, air cleaner elements may require

more frequent replacement.

Engine Air Cleaner Element -

If equipped, perform maintenance on the pre-cleaner

Replace

or the dust bowl before performing maintenance on

the air filter elements.

NOTICE

Never run the engine without an air cleaner element

installed. Never run the engine with a damaged air

cleaner element. Do not use air cleaner elements

with damaged pleats, gaskets or seals. Dirt entering

the engine causes premature wear and damage to

engine components. Air cleaner elements help to pre-

vent airborne debris from entering the air inlet.

NOTICE

Never service the air cleaner element with the engine

running since this will allow dirt to enter the engine.

Ensure that the engine cannot start before any

service or repair is performed.

Servicing the Air Cleaner Element

Note: The air filter system may not have been

provided by Perkins. The procedure that follows is for

Illustration 84

g06043462

a typical air filter system. Refer to the OEM

Typical example

information for the correct procedure.

Note: Do not allow dirt to enter the air system during

If the air cleaner element becomes plugged, the air

replacement of the air filter elements.

can split the material of the air cleaner element.

Unfiltered air will drastically accelerate internal

engine wear. Refer to the OEM information for the

1. Clean the outer casing of the air cleaner before

correct air cleaner elements for your application.

removing the end cover (3).

• Check the air cleaner service indicator daily.

Note: Before removal, check the orientation of the

end cover (3). Some air cleaners the end cover must

be installed in the correctly aligned position.

M0076814-03

Maintenance Section

Engine Air Cleaner Service Indicator - Inspect

2. Release the clips (4) and remove the end cover (3)

• The yellow diaphragm enters the red zone.

from air cleaner body (1).

• The red piston locks in the visible position.

3. Remove the primary air filter element (2) and

remove the secondary air filter element (not

Test the Service Indicator

shown) from air cleaner body (1). Ensure that the

inner body of the air cleaner is clean and free from

Service indicators are important instruments.

dirt. Ensure that the inner of the air cleaner cover ,

• Check for ease of resetting. The service indicator

(3) is clean and free from dirt.

should reset in less than three pushes.

4. Install a new secondary air filter element (not

• Check the movement of the service indicator core

shown). Install a new primary air filter element (2)

when the engine is run at full load speed. The core

and install end cover (3). Ensure that the clips (4)

should latch approximately at the greatest vacuum

are located securely.

that is attained.

i06103548

If the service indicator does not reset easily, or if the

core does not latch at the greatest vacuum, the

service indicator should be replaced. If the new

Engine Air Cleaner Service

service indicator will not reset, the hole for the service

Indicator - Inspect

indicator may be plugged.

(If Equipped)

If necessary, replace the service indicator more

frequently in environments that are severely dusty.

Replace the service indicator annually regardless of

the operating conditions. Replace the service

Some engines may be equipped with a different

indicator when the engine is overhauled, and

service indicator.

whenever major engine components are replaced.

Some engines are equipped with a differential gauge

for inlet air pressure. The differential gauge for inlet

Note: When a new service indicator is installed,

air pressure displays the difference in the pressure

excessive force may crack the top of the service

that is measured before and after the air cleaner

indicator. Tighten the service indicator to a torque of

element. As the air cleaner element becomes dirty,

2 N·m (18 lb in).

the pressure differential rises. If your engine is

equipped with a different type of service indicator,

i07819538

follow the OEM recommendations in order to service

the air cleaner service indicator.

Engine Mounts - Inspect

The service indicator may be mounted on the clean

side of the air cleaner housing or in a remote

location.

Note: The engine mounts may not have been

supplied by Perkins. Refer to the Original Equipment

Manufacturer (OEM information for further details on

the engine mounts and the correct bolt torque.

Inspect the engine mounts for deterioration and for

correct bolt torque. Excessive engine vibration can

be caused by the following conditions:

• Incorrect mounting of the engine

• Deterioration of the engine mounts

• Loose engine mounts

Any engine mount that shows deterioration should be

replaced. Refer to the OEM information for the

Illustration 85

g00103777

recommended torques.

Typical service indicator

When the engine mounts are supplied by Perkins the

Observe the service indicator. The air cleaner

maintenance procedure will be supplied in the

element should be cleaned or the air cleaner element

Disassembly and Assembly manual for your engine.

should be replaced when one of the following

conditions occur:

M0076814-03

Maintenance Section

Engine Oil Level - Check

i06826917

NOTICE

Engine damage can occur if the crankcase is filled

Engine Oil Level - Check

above the “FULL” mark on the oil level gauge

(dipstick).

An overfull crankcase can cause the crankshaft to dip

into the oil. This will reduce the power that is devel-

oped and also force air bubbles into the oil. These

Hot oil and hot components can cause personal

bubbles (foam) can cause the following problems: re-

injury. Do not allow hot oil or hot components to

duction of the oil's ability to lubricate, reduction of oil

contact the skin.

pressure, inadequate cooling, oil blowing out of the

crankcase breathers and excessive oil consumption.

Excessive oil consumption will cause deposits to form

on the pistons and in the combustion chamber. De-

posits in the combustion chamber lead to the follow-

ing problems: guttering of the valves, packing of

carbon under the piston rings and wear of the cylin-

der liner.

If the oil level is above the “FULL” mark on the oil lev-

el gauge, drain some of the oil immediately.

1. Remove the oil level gauge to check engine oil

level. Maintain the oil level between the “ADD”

mark (Y) and the “FULL” mark (X) on the oil level

gauge (2). Do not fill the crankcase above “FULL”

mark (X).

2. If engine oil is required, remove oil filler cap to add

engine oil.

3. To choose the correct type of oil for this engine,

refer to this Operation and Maintenance Manual,

Illustration 86

g06131517

“Fluid Recommendations”.

Typical example

4. Clean the oil filler cap and install the oil filler cap.

(1) Oil filler cap

(2) Oil level gauge (Dipstick)

5. Record the amount of oil that is added. For the

next oil sample and analysis, include the total

amount of oil that has been added since the

previous sample. Recording this information helps

to provide the most accurate oil analysis.

i01907674

Engine Oil Sample - Obtain

Illustration 87

g00110310

Partial view of the oil level gauge

The condition of the engine lubricating oil may be

(Y) “ADD” mark

checked at regular intervals as part of a preventive

(X) “FULL” mark

maintenance program. Perkins include an oil

sampling valve as an option. The oil sampling valve

(if equipped) is included in order to regularly sample

NOTICE

the engine lubricating oil. The oil sampling valve is

Perform this maintenance with the engine stopped.

positioned on the oil filter head or the oil sampling

valve is positioned on the cylinder block.

M0076814-03

Maintenance Section

Engine Oil and Filter - Change

Perkins recommends using a sampling valve in order

The sample can be checked for the following: the

to obtain oil samples. The quality and the consistency

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

of the samples are better when a sampling valve is

oil, the existence of any ferrous metal particles in the

used. The location of the sampling valve allows oil

oil and the existence of any nonferrous metal

that is flowing under pressure to be obtained during

particles in the oil.

normal engine operation.

i06826973

Obtain the Sample and the

Engine Oil and Filter - Change

Analysis

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to

Hot oil and hot components can cause personal

contact the skin.

injury. Do not allow hot oil or hot components to

contact the skin.

In order to help obtain the most accurate analysis,

record the following information before an oil sample

is taken:

Oil and Filter Change Intervals

• The date of the sample

The standard engine oil and filter change period is

• Engine model

500 hours. There are several other factors that can

alter the standard engine oil and filter change of 500

• Engine number

hours.

• If the engine is using engine oil analysis to

• Service hours on the engine

determine oil and filter change period.

• The number of hours that have accumulated since

• The engine is working in a severe service

the last oil change

environment/Load Factor

• The amount of oil that has been added since the

• Infrequent operation of the engine

last oil change

Ensure that the container for the sample is clean and

Refer to this Operation and Maintenance Manual,

dry. Also ensure that the container for the sample is

“Severe Service Application” for more information on

clearly labelled.

reducing the engine oil and filter change period. For

severe service applications the recommended oil and

To ensure that the sample is representative of the oil

filter change period is 250 hours.

in the crankcase, obtain a warm, well mixed oil

sample.

If the engine is operated in severe service conditions,

Perkins recommends the use of engine oil sampling.

To avoid contamination of the oil samples, the tools

Refer to this Operation and Maintenance Manual,

and the supplies that are used for obtaining oil

Engine Oil sample - Obtain for more information.

samples must be clean.

If the engine is operated infrequently less than 500

hours in a 12-month period, then the engine oil and

filter change should be conducted yearly.

Drain the Engine Lubricating Oil

NOTICE

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.

M0076814-03

Maintenance Section

Engine Oil and Filter - Change

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

Do not drain the engine lubricating oil when the

engine is cold. As the engine lubricating oil cools,

suspended waste particles settle on the bottom of the

oil pan. The waste particles are not removed with

draining cold oil. Drain the oil pan with the engine

stopped. Drain the oil pan with the oil warm. This

draining method allows the waste particles that are

suspended in the oil to be drained properly.

Failure to follow this recommended procedure will

cause the waste particles to be recirculated through

the engine lubrication system with the new oil.

Note: Ensure that the vessel that will be used is large

enough to collect the waste oil.

After the engine has been run at the normal

operating temperature, stop the engine. Use one of

Illustration 88

g06131554

the following methods to drain the engine oil pan:

Typical example

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

2. Clean sealing surface (1).

the drain valve knob counterclockwise to drain the

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

3. Apply clean engine oil to O ring seal (2) for the new

knob clockwise to close the drain valve.

oil filter (3).

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

NOTICE

remove the oil drain plug to allow the oil to drain.

Do not fill the oil filter with oil before installing. This oil

would not be filtered and could be contaminated.

After the oil has drained, the oil drain plug should be

Contaminated oil can cause accelerated wear to en-

cleaned. If necessary, replace the O ring seal and

gine components.

install the plug. Tighten the drain plug to 35 N·m

(26 lb ft).

4. Install the new oil filter (3). Spin on the oil filter until

Replace the Oil Filter

the O ring contacts the sealing surface (1). Then

rotate the oil filter 1 full turn. Remove the container

NOTICE

and disposal of the waste oil in accordance with

Perkins oil filters are manufactured to Perkins specifi-

local regulations.

cations. Use of an oil filter that is not recommended

by Perkins could result in severe damage to the en-

Fill the Oil Pan

gine bearings, and crankshaft. As a result of the larg-

er waste particles from unfiltered oil entering the

engine lubricating system. Only use oil filters recom-

1. Remove the oil filler cap. Refer to this Operation

mended by Perkins.

and Maintenance Manual, “Fluid

Recommendations” for more information on

suitable oils. Fill the oil pan with the correct

1. Remove the oil filter with a suitable tool.

amount of new engine lubricating oil. Refer to this

Operation and Maintenance Manual, “Refill

Capacities” for more information on refill

capacities.

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

for 2 minutes. Perform this procedure to ensure

that the lubrication system has filled the oil filter.

Inspect the oil filter for oil leaks.

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

the oil pan for a minimum of 10 minutes.

100

M0076814-03

Maintenance Section

Engine Storage Procedure - Check

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

4. Drain the crankcase oil. Replace the crankcase oil

Maintain the oil level between the ADD and FULL

and change the oil filters. For the proper

marks on the side of the oil level gauge.

procedure, refer to this Operation and

Maintenance Manual.

i06836189

5. Add Volatile Corrosion Inhibitor (VCI) oil to the

crankcase oil. The volume of VCI oil in the

Engine Storage Procedure -

crankcase oil should be 3 to 4 percent.

Check

Note: If the engine crankcase is full, drain enough

engine oil so the mixture can be added.

The oil change interval may be extended to 12

6. Remove the air filter elements. Turn the engine at

months for a vehicle that is operated seasonally and

cranking speed with the throttle control in FUEL

placed in storage for the remainder of the year by

using the required storage procedures and the

OFF position. Use a sprayer to add a mixture of 50

required start-up procedures. This extension is

percent VCI oil and 50 percent engine oil into the

permitted if the following categories for oil change

air inlet or turbocharger inlet.

intervals in the Operation and Maintenance Manual,

Maintenance Interval Schedule have not been

Note: The mixture of VCI oil can be added to the inlet

reached:

by removing the plug for checking turbocharger boost

pressure. The minimum application rate for the VCI

• Mileage

oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of

engine displacement.

• Operating hours

• Fuel consumption

7. Use a sprayer to apply a mixture of 50 percent VCI

oil and 50 percent crankcase oil into the exhaust

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

openings. The minimum application rate for the oil

engine is not planned, special precautions should be

mixture is 5.5 mL per L (3 oz per 1000 cu in) of

made. If the engine will be stored for more than 3

engine displacement. Seal the exhaust pipe and

months, a complete protection procedure is

recommended.

seal any drain holes in the muffler.

8. Remove the fuel from the secondary fuel filter

Special Precautions

housing. Alternately, empty and reinstall the spin-

on fuel filter element to remove any dirt and water.

Your Perkins distributor can help in preparing the

Drain any sleeve metering fuel pump.

engine for extended storage periods.

Clean the primary fuel filter. Fill with calibration

Some applications, the engine can be equipped with

fluid or kerosene. Install the primary fuel filter and

delayed engine shutdown. Allow at least 2 minutes

operate the priming pump. This procedure will

after the engine has stopped before you turn the

send clean oil to the secondary filter and the

battery disconnect switch to OFF. Disconnecting the

battery power too soon will prevent purging of the

engine.

DEF fluid lines after the engine is shut down. Also,

Open the fuel tank drain valve to drain any water

during the 2 minutes the engine electronic control

module is active storing information from the engine

and dirt from the fuel tank. Apply a spray of

and aftertreatment sensors.

calibration fluid or kerosene at the rate of

30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank

The OEM condition of storage for the application that

capacity to prevent rust in the fuel tank. Add

the engine is installed must be followed.

0.15 mL per L (.02 oz per 1 gal US) of commercial

biocide such as Biobor JF to the fuel.

Engine

Apply a small amount of oil to the threads on the

1. Clean the engine of any dirt, rust, grease, and oil.

fuel tank filler neck and install the cap. Seal all

Inspect the exterior. Paint areas that contain paint

openings to the tank to prevent evaporation of the

damage with a good quality paint.

fuel and as a preservative.

2. Remove dirt from the air cleaners. Check all seals,

9. Remove the fuel injectors. Apply 30 mL (1 oz) of

gaskets, and the filter element for damage.

the mixture of oils (50 percent VCI oil and 50

percent engine oil) into each cylinder.

3. Apply lubricant to all points in this Operation and

Maintenance Manual, “Maintenance Interval

Schedule”.

M0076814-03

101

Maintenance Section

Engine Storage Procedure - Check

Use a bar or a turning tool to turn over the engine

Refer to this Operation and Maintenance Manual,

slowly. This procedure puts the oil on the cylinder

“Fluid Recommendations” for more information about

coolants.

walls. Install all fuel injectors and tighten to the

correct torque. Refer to Disassembly and

Aftertreatment

Assembly Manual for more information.

10. Spray a thin amount of a mixture of 50 percent

The engine must be allowed to perform a Diesel

Exhaust Fluid (DEF) purge before the battery

VCI oil and 50 percent engine oil onto the following

disconnect switch is turned off. Some applications,

components: flywheel, ring gear teeth, and starter

the engine can be equipped with delayed engine

pinion. Install the covers to prevent evaporation of

shutdown. Allow 2 minutes after the engine has

the vapors from the VCI oil.

stopped before disconnecting the battery disconnect

switch.

11. Apply a heavy amount of Multipurpose Grease to

all outside parts that move, such as rod threads,

The exhaust outlet of the aftertreatment must be

ball joints, linkage.

capped. To prevent damage to the exhaust outlet

connection during storage, the weight of the CEM

Note: Install all covers. Ensure that tape has been

must not act on the exhaust outlet.

installed over all openings, air inlets, exhaust

1. Ensure normal engine shutdown, allow the DEF to

openings, the flywheel housing, the crankcase

be purged. Do not disconnect the battery

breathers, the dipstick tubes.

disconnect switch, allow 2 minutes after key off

Ensure that all covers are airtight and

before disconnection.

weatherproof. Use a waterproof weather resistant

2. Fill the tank with DEF that meets all the

tape such as Kendall No. 231 or an equivalent. Do

requirement defined in ISO 22241-1.

not use duct tape. Duct tape will only seal for a

short time.

3. Ensure that all DEF lines and electrical connection

are connected prior to prevent crystal from

12. Under most conditions, removing the batteries is

forming.

the best procedure. As an alternative, place the

batteries in storage. As needed, periodically

4. Ensure that the DEF filler cap is correctly installed.

charge the batteries whilst the batteries are in

storage.

Removing Application from

Storage

If the batteries are not removed, wash the tops of

the batteries until the tops are clean. Apply an

Follow the OEM recommendation for application

electrical charge to the batteries to obtain a

removal from storage.

specific gravity of 1.225.

Disconnect the battery terminals. Place a plastic

Remove Engine from Storage

cover over the batteries.

1. Remove all outside protective covers.

13. Remove the drive belts from the engine

2. Change the oil and filters.

14. Place a waterproof cover over the engine. Ensure

that the engine cover is secure. The cover should

3. Check the condition of the fan and alternator belts.

be loose enough to allow air to circulate around

Replace the belts, if necessary. Refer to this

the engine to prevent damage from condensation.

Operation and Maintenance Manual, “Belts -

Inspect/Adjust/Replace” for the correct procedure.

15. Attach a tag with the storage date to the engine.

4. Replace the fuel filter elements.

16. Remove the waterproof cover at 2 month or 3-

month intervals to check the engine for corrosion.

5. Remove the plastic covers from the air cleaner

If the engine has signs of corrosion, repeat the

elements.

protection procedure.

6. Use a bar or a turning tool to turn the engine in the

normal direction of rotation. The procedure

Coolant System

ensures that no hydraulic locks or resistance exist.

Completely fill the cooling system before storage.

7. Before starting the engine, remove the valve cover

or covers. Put a large amount of engine oil on the

camshaft, cam followers, and valve mechanism to

prevent damage to the mechanism.

102

M0076814-03

Maintenance Section

Engine Storage Procedure - Check

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.

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.

Remove Aftertreatment from

Storage

DEF has a limited life, refer to table 17 for the time

and temperature range. DEF that is outside this

range MUST be replaced.

On removal from storage the DEF quality in the tank

must be tested with a refractometer. The DEF in the

Illustration 89

g06042459

tank must meet the requirements defined in ISO

Typical example

22241-1 and comply with table 17 .

(1) Plug

1. If necessary, drain the tank and fill with DEF that

meets ISO 22241-1.

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

recommends Pre lubrication of the engine to avoid

2. Replace the DEF filter, refer to this Operation, and

dry starting. Use a suitable pump to put engine oil

Maintenance Manual, “Diesel Exhaust Fluid Filter-

into the engine oil system.

Clean/Replace”.

The pump will need to create a minimum pressure

3. Ensure that the drive belt is correctly installed.

within the engine of 0.25 bar (3.6 psi). This

Ensure that all engine coolant and engine oil has

pressure is needed for 15 seconds to lubricate the

the correct specification and grade. Ensure that

internal surfaces.

the coolant and the engine oil are at the correct

level. Start the engine. If a fault becomes active

Remove one of the plugs shown in illustration 89

turn off the engine, allow 2 minutes for the DEF

to connect to the engine oil system. The

system to purge, then restart the engine.

connection required is 9/16" x 18 tpi. Ensure that

the correct oil specification is used, refer to this

4. If the fault continues to stay active, refer to

Operation and Maintenance Manual, “Fluid

Troubleshooting for more information.

Recommendations” for more information. After the

Table 17

engine internal surfaces have been lubricated,

DEF Storage

remove connector and install plug (1). Tighten plug

Temperature

Duration

to a torque of 30 N·m (265 lb in). Perkins

recommends that the procedure must be

10° C (50° F)

36 months

performed in a minimum ambient temperature of

25° C (77° F)

18 months

10° C (50° F).

9. Check the condition of all rubber hoses. Replace

any worn hoses. Replace any damaged hoses.

(continued)

M0076814-03

103

Maintenance Section

Engine Valve Lash - Check

(Table 17, contd)

During valve adjustment, visibly inspect the valve

train of wear or damage.

30° C (86° F)

12 months

35° C (95° F)⁽¹⁾

6 months

Refer to Systems Operation, Testing and Adjusting,

“Engine Valve Lash - Inspect/Adjust” for more

⁽¹⁾ At 35° C, significant degradation can occur. Check every batch

information.

before use.

i06827467

Additional Information

Fuel System - Prime

The volatile vapors are removed by running the

engine to operating temperature. A mineral oil base

is left behind after the volatile vapors are removed.

The oil should then be drained, and new oil and filters

NOTICE

installed.

Do not allow dirt to enter the fuel system. Thoroughly

clean the area around a fuel system component that

i07192202

will be disconnected. Fit a suitable cover over any

disconnected fuel system components.

Engine Valve Lash - Check

Ensure that the engine cannot 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.

NOTICE

Only qualified service personel should perform this

maintenance. Refer to the Service Manual or your au-

thorized Perkins dealer or your Perkins distributor for

the complete valve lash adjustment procedure.

Operation of Perkins engines with incorrect valve

lash can reduce engine efficiency, and also reduce

engine component life.

Illustration 90

g06046130

The initial valve lash adjustment on new engines,

(1) Fuel priming pump

rebuilt engines, or remanufactured engines is

(2) Fuel priming switch

recommended only on engine ratings 432 kW

(580 hp) and greater. The adjustment is necessary

1. The fuel system can be primed from the keyswitch

due to the initial wear of the valve train components

or from a remote mounted switch (2).

and to the seating of the valve train components.

2. Turn the fuel priming switch (2) to the ON position.

This maintenance is recommended as part of a

Hold the fuel priming switch in the ON position for

lubrication and preventive maintenance schedule to

2 minutes. If the fuel system is being primed from

help provide maximum engine life. For engine ratings

less than 432 kW (580 hp), the initial valve lash

empty, then turn the switch off and then on again

adjustment is not necessary.

for 2 minutes.

Note: All engine ratings must have the engine valve

3. After 2 minutes the fuel system should be primed

lash performed at 2500 hours.

and the engine ready to start.

Ensure that the engine is stopped before measuring

4. Start the engine, refer to this Operation and

the valve lash. To obtain an accurate measurement,

Maintenance Manual, Starting the Engine or refer

allow the valves to cool before this maintenance is

to the OEM for instructions on starting the engine.

performed.

104

M0076814-03

Maintenance Section

Fuel System Primary Filter (Water Separator) Element - Replace

5. If the engine starts and the engine runs rough or

the engine misfires, operate at low idle until the

engine is running smoothly. If the engine cannot

be started, or if the engine continues to misfire or

smoke, repeat Step 2.

The fuel system can also be primed by using the key

switch. Turn the key to the ON position for 2 minutes.

After 2 minutes the fuel system should be primed. If

necessary, by cycling the key switch the system will

prime again for 2 minutes.

i06614133

Fuel System Primary Filter

(Water Separator Element -

Replace

Illustration 91

g06046186

Fuel leaked or spilled onto hot surfaces or electri-

1. Close the main fuel supply valve.

cal components can cause a fire. To help prevent

possible injury, turn the start switch off when

2. Place a suitable container below the primary fuel

changing fuel filters or water separator elements.

filter to catch any fluid that may spill. Clean any

Clean up fuel spills immediately.

split fluid.

3. Clean the outside of the primary fuel filter.

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly

4. Using a suitable tool, remove the spin on filter (4)

clean the area around a fuel system component that

from filter base (1). Discard old filter element.

will be disconnected. Fit a suitable cover over any

disconnected fuel system components.

5. Ensure the seal surface (2) is clean. Apply clean

diesel fuel to the O ring seal (3) on the new spin on

filter.

NOTICE

Do not fill fuel filters with fuel before installing

6. Install the new spin on filter to the filter base (1).

them. The fuel will not be filtered and could be

Spin on the filter until the O ring seal (3) contact

contaminated. Contaminated fuel will cause ac-

the sealing surface (2). Then, rotate the spin on

celerated wear to fuel system parts. The fuel sys-

filter ¾ of a full turn.

tem should be primed prior to starting the engine.

7. The secondary fuel filter should be replaced when

Water in the fuel can cause the engine to run rough.

the primary fuel filter is replaced. For more

Water in the fuel may cause an electronic unit injector

to fail. If the fuel has been contaminated with water,

information refer to this Operation and

the element should be changed before the regularly

Maintenance Manual, “Fuel System Secondary

scheduled interval.

Filter - Replace”.

The primary filter/water separator also provides

8. Dispose of the fluid and old filter in accordance

filtration to help extend the life of the secondary fuel

with local regulations.

filter. The element should be changed regularly. If a

vacuum gauge is installed, the primary filter/water

separator should be changed at 50 kPa to 70 kPa

(7.25 psi to 10.15 psi).

M0076814-03

105

Maintenance Section

Fuel System Primary Filter/Water Separator - Drain

i06616051

i06605835

Fuel System Primary Filter/

Fuel System Secondary Filter -

Water Separator - Drain

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 any

disconnected fuel system components.

NOTICE

Ensure that the engine is stopped before any servic-

ing or repair is performed.

Refer to Systems Operation, Testing, and

Adjusting, “Cleanliness of Fuel System

Components” for detailed information on the

standards of cleanliness that must be observed

during ALL work on the fuel system.

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

performing this maintenance.

2. Place a suitable container under the fuel filters to

catch any fuel that might spill. Clean up any spilled

fuel. Clean the outside body of both fuel filters.

Illustration 92

g03807817

Typical example

1. Ensure that the engine is stopped. Open drain (1).

The drain is a self-ventilated drain. Catch the

draining water in a suitable container. Dispose of

the water properly.

2. Close drain (3).

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.

106

M0076814-03

Maintenance Section

Fuel Tank Water and Sediment - Drain

i02348492

Fuel Tank Water and Sediment

- Drain

NOTICE

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.

Fuel Tank

Fuel quality is critical to the performance and to the

Illustration 93

g06042986

service life of the engine. Water in the fuel can cause

Typical example

excessive wear to the fuel system.

Water can be introduced into the fuel tank when the

Note: The fuel system has two secondary filters, both

fuel tank is being filled.

must be replaced.

Condensation occurs during the heating and cooling

3. The residual fuel pressure in the fuel system may

of fuel. The condensation occurs as the fuel passes

need relieving. Wait from 1 minute to 5 minutes

through the fuel system and the fuel returns to the

until the fuel pressure has lowered.

fuel tank. This causes water to accumulate in fuel

tanks. Draining the fuel tank regularly and obtaining

4. Use a suitable tool remove the spin on fuel filter

fuel from reliable sources can help to eliminate water

(3).

in the fuel.

5. Ensure the sealing surface (1) is clean. Lubricate

Drain the Water and the Sediment

the O ring seal (2) on the new spin on filter with

clean diesel fuel.

Fuel tanks should contain some provision for draining

water and draining sediment from the bottom of the

6. Install the new spin on filter (3) to the filter base.

fuel tanks.

Spin on the filter until the O ring seal (2) contact

the sealing surface (1). Then, rotate the spin on

Open the drain valve on the bottom of the fuel tank in

order to drain the water and the sediment. Close the

filter 1 full turn.

drain valve.

7. Replace the other secondary fuel filter, refer to

Check the fuel daily. Allow five minutes after the fuel

step 2 through to step 6.

tank has been filled before draining water and

sediment from the fuel tank.

8. Turn on the fuel supply valve. Dispose of the fluid

and old filters in accordance with local regulations.

Fill the fuel tank after operating the engine in order to

drive out moist air. This will help prevent

9. The primary fuel filter the secondary fuel filter must

condensation. Do not fill the tank to the top. The fuel

be replaced at the same time. Refer to the

expands as the fuel gets warm. The tank may

Operation and Maintenance Manual, “Fuel System

overflow.

Primary Filter (Water Separator) Element -

Replace”. The engine will need to be purged of air.

With primary and secondary fuel filters replace,

Refer to Operation and Maintenance Manual,

“Fuel System Prime”.

M0076814-03

107

Maintenance Section

Grounding Stud - Inspect/Clean/Tighten

Some fuel tanks use supply pipes that allow water

The grounding stud must have a wire ground to the

and sediment to settle below the end of the fuel

battery. Tighten the grounding stud at every oil

supply pipe. Some fuel tanks use supply lines that

change. Ground wires and straps should be

take fuel directly from the bottom of the tank. If the

combined at engine grounds. All grounds should be

engine is equipped with this system, regular

tight and free of corrosion.

maintenance of the fuel system filter is important.

• Clean the grounding stud and the terminals for the

ground strap with a clean cloth.

Fuel Storage Tanks

• If the connections are corroded, clean the

Drain the water and the sediment from the fuel

connections with a solution of baking soda and

storage tank at the following intervals:

water.

• Weekly

• Keep the grounding stud and the strap clean and

• Service intervals

coated with MPGM grease or petroleum jelly.

• Refill of the tank

i06103230

This will help prevent water or sediment from being

pumped from the storage tank into the engine fuel

Hoses and Clamps - Inspect/

tank.

Replace

If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to

settle before filling the engine fuel tank. Internal

baffles in the bulk storage tank will also help trap

sediment. Filtering fuel that is pumped from the

storage tank helps to ensure the quality of the fuel.

Contact with high pressure fuel may cause fluid

When possible, water separators should be used.

penetration and burn hazards. High pressure fuel

spray may cause a fire hazard. Failure to follow

these inspection, maintenance and service in-

i03965989

structions may cause personal injury or death.

Grounding Stud - Inspect/

If you inspect the engine in operation, always use the

proper inspection procedure in order to avoid a fluid

Clean/Tighten

penetration hazard. Refer to Operation and

Maintenance Manual, “General hazard Information”.

Inspect all hoses for leaks that are caused by the

following conditions:

• Cracking

• Softness

• Loose clamps

Replace hoses that are cracked or soft. Tighten any

loose clamps.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

Illustration 94

g01376112

The grounding stud is located on the upper left corner

• Exposed wire that is used for reinforcement

of the engine control module.

• Outer covering that is ballooning locally

Inspect the OEM harness for good connections.

• Flexible part of the hose that is kinked or crushed

Inspect the condition of the OEM harness.

• Armoring that is embedded in the outer covering

108

M0076814-03

Maintenance Section

Overhaul Considerations

A constant torque hose clamp can be used in place

8. Refill the cooling system. Refer to the OEM

of any standard hose clamp. Ensure that the constant

information for further information on refilling the

torque hose clamp is the same size as the standard

cooling system.

clamp.

9. Clean the cooling system filler cap. Inspect the

Due to extreme temperature changes, the hose will

cooling system filler caps seals. Replace the

harden. Hardening of the hoses will cause hose

cooling system filler cap if the seals are damaged.

clamps to loosen. This hardening can result in leaks.

A constant torque hose clamp will help to prevent

Install the cooling system filler cap.

loose hose clamps.

10. Start the engine. Inspect the cooling system for

Each installation application can be different. The

leaks.

differences depend on the following factors:

Fuel System

• Type of hose

The fuel system is split into two different sections,

• Type of fitting material

high pressure, and low pressure. Ensure that the fuel

pressure has been purged before any parts are

• Anticipated expansion and contraction of the hose

removed loosened or replaced.

• Anticipated expansion and contraction of the

Check that connections and hoses are secure, check

fittings

for leaks. If parts are to be removed or tightened,

refer to the Disassembly and Assembly manual for

Replace the Hoses and the Clamps

more information.

Refer to the OEM information for further information

i05971077

on removing and replacing fuel hoses (if equipped).

Overhaul Considerations

The following text describes a typical method of

replacing coolant hoses. Refer to the OEM

information for further information on the coolant

system and the hoses for the coolant system.

For an overhaul solution, contact your Perkins

distributor.

i03901481

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,

Power Take-Off Clutch - Check

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure cap slowly in order to relieve the

pressure.

NOTICE

New power take-offs should have the clutch adjust-

ment checked before being placed into service. The

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

clutch adjustment should be checked again after the

first ten hours of operation. New clutch plates have a

2. Loosen the cooling system filler cap slowly in order

“wear in” period, and the clutch may require several

to relieve any pressure. Remove the cooling

adjustments until the new plates are “worn in”.

system filler cap.

Note: Drain the coolant into a suitable, clean

container. The coolant can be reused.

3. Drain the coolant from the cooling system to a

level that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: For the correct coolant, see this Operation and

Maintenance Manual, “Fluid Recommendations”.

M0076814-03

109

Maintenance Section

Radiator - Clean

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.

The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the air

nozzle is deadheaded.

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction of

the air flow. Hold the nozzle approximately 6 mm

Illustration 95

g00781502

(0.25 inch) away from the fins. Slowly move the air

(1) Instruction plate

nozzle in a direction that is parallel with the tubes.

(2) Serial number plate

This movement will remove debris that is between

the tubes.

Check the clutch adjustment regularly after “wear in”.

Pressurized water may also be used for cleaning.

Heavy-duty applications which have engagements

The maximum water pressure for cleaning purposes

that are frequent and relatively long periods of clutch

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

slippage require more frequent adjustment than light-

water to soften mud. Clean the core from both sides.

duty applications. The operating torque should be

measured in order to determine if a clutch adjustment

Use a degreaser and steam for removal of oil and

is required.

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

with detergent and hot water. Thoroughly rinse the

Refer to the OEM information and instruction plate

core with clean water.

(1) for instructions on lubrication, adjustment, and

other recommendations for service. Perform the

After cleaning, start the engine and bring the engine

maintenance that is specified on the instruction plate.

to high idle. This procedure will help in the removal of

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

light bulb behind the core to inspect the core for

cleanliness. Repeat the cleaning, if necessary.

Do not operate the engine with the Instruction

Inspect the fins for damage. Bent fins may be opened

Plate cover removed from the clutch. Personal in-

jury may result.

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

welds, mounting brackets, air lines, connections,

If the clutch is damaged to the point of burst fail-

clamps, and seals. Make repairs, if necessary.

ure, expelled pieces can cause personal injury to

anyone in the immediate area. Proper safeguards

i02568202

must be followed to help prevent accidents.

Starting Motor - Inspect

i08254039

Perkins recommends a scheduled inspection of the

Radiator - Clean

starting motor. If the starting motor fails, the engine

may not start in an emergency situation.

Check the starting motor for proper operation. Check

Note: Adjust the frequency of cleaning according to

the electrical connections and clean the electrical

the effects of the operating environment.

connections. Refer to the Service Manual for more

information on the checking procedure and for

Inspect the radiator for these items: damaged fins,

specifications or consult your Perkins distributors for

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

assistance.

debris. Clean the radiator, if necessary.

110

M0076814-03

Maintenance Section

Walk-Around Inspection

i06101140

• Inspect the fuel system for leaks. Look for loose

fuel line clamps or for loose fuel line tie-wraps.

Walk-Around Inspection

• 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

Inspect the Engine for Leaks and

hoses, tubes, and wiring harnesses.

for Loose Connections

• Inspect the alternator belt and the accessory drive

belts for cracks, breaks, or other damage.

A walk-around inspection should only take a few

minutes. When the time is taken to perform these

Belts for multiple groove pulleys must be replaced as

checks, costly repairs and accidents can be avoided.

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

carry more load than the belts that are not replaced.

For maximum engine service life, make a thorough

The older belts are stretched. The additional load on

inspection of the engine compartment before starting

the new belt could cause the belt to break.

the engine. Look for items such as oil leaks or

coolant leaks, loose bolts, worn belts, loose

• Drain the water and the sediment from fuel tanks

connections, and trash buildup. Make repairs, as

on a daily basis in order to ensure that only clean

needed:

fuel enters the fuel system.

• The guards must be in the proper place. Repair

• Inspect the wiring and the wiring harnesses for

damaged guards or replace missing guards.

loose connections and for worn wires or frayed

wires.

• Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system

• Inspect the ground strap for a good connection

contamination.

and for good condition.

NOTICE

• Inspect the ECM to the cylinder head ground strap

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

for a good connection and for good condition.

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

correct the leak. If leaking is suspected, check the flu-

• Disconnect any battery chargers that are not

id levels more often than recommended until the leak

protected against the current drain of the starting

is found or fixed, or until the suspicion of a leak is

motor. Check the condition and the electrolyte

proved to be unwarranted.

level of the batteries, unless the engine is

equipped with a maintenance free battery.

NOTICE

• Check the condition of the gauges. Replace any

Accumulated grease and/or oil on an engine or deck

gauges that are cracked. Replace any gauge that

is a fire hazard. Remove this debris with steam clean-

cannot be calibrated.

ing or high pressure water.

Aftertreatment System

• Ensure that the cooling lines are properly clamped

Check the condition of the coolant lines, Diesel

and that the cooling lines are tight. Check for

Exhaust Fluid (DEF) lines, and electrical

leaks. Check the condition of all pipes.

connections. Check that all clamps, clips, and tie-

wraps are secure and in good condition. Check that

• Inspect the water pumps for coolant leaks.

the DEF filler cap is secure and that the cap is clean

and free from dirt.

Note: The water pump seal is lubricated by coolant in

the cooling system. It is normal for a small amount of

Check the level of DEF in the tank is adequate for

leakage to occur as the engine cools down and the

operational purpose, if necessary fill the DEF tank.

parts contract.

Excessive coolant leakage may indicate the need to

replace the water pump seal. For the removal of

water pumps and the installation of water pumps and/

or seals, refer to the Service Manual for the engine or

consult your Perkins distributor .

• Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil

pan, the oil filters, and the valve cover.

M0076814-03

111

Warranty Section

Warranty Information

3. New non-road diesel engines installed in

Warranty Section

construction machines conforming to theSouth

Korean regulations for construction machines

manufactured after January 1, 2015, and operated

Warranty Information

and serviced inSouth Korea, including all parts of

their emission control systems (“emission related

i07304835

components”), are:

Emissions Warranty

a. Designed, built, and equipped so as to conform,

at the time of sale, with applicable emission

Information

standards prescribed in the Enforcement Rule

of the Clean Air Conservation Act promulgated

by South Korea MOE.

The certifying engine manufacturer warrants to the

ultimate purchaser and each subsequent purchaser

b. Free from defects in materials and

that:

workmanship in emission-related components

that can cause the engine to fail to conform to

1. New non-road diesel engines and stationary diesel

applicable emission standards for the warranty

engines less than 10 L per cylinder (including Tier

period.

1 and Tier 2 marine engines < 37 kW, but

excluding locomotive and other marine engines)

The aftertreatment system can be expected to

operated and serviced in the United States and

function properly for the lifetime of the engine

Canada, including all parts of their emission

(emissions durability period) subject to prescribed

control systems (“emission-related components”),

maintenance requirements being followed.

are:

For a detailed explanation of the Emission Control

a. Designed, built, and equipped so as to conform,

Warranty, contact your authorized Perkins dealer or

your authorized Perkins distributor.

at the time of sale, with applicable emission

standards prescribed by the United States

Environmental Protection Agency (EPA) by way

of regulation.

b. Free from defects in materials and

workmanship in emission-related components

that can cause the engine to fail to conform to

applicable emission standards for the warranty

period.

2. New non-road diesel engines (including Tier 1 and

Tier 2 marine propulsion engines < 37 kW and Tier

1 through Tier 4 marine auxiliary engines < 37 kW,

but excluding locomotive and other marine

engines) operated and serviced in the state of

California, including all parts of their emission

control systems (“emission-related components”),

are:

a. Designed, built, and equipped so as to conform,

at the time of sale, to all applicable regulations

adopted by the California Air Resources Board

(ARB).

b. Free from defects in materials and

workmanship which cause the failure of an

emission-related component to be identical in

all material respects to the component as

described in the engine manufacturer's

application for certification for the warranty

period.

112

M0076814-03

Reference Information Section

Reference Materials

www.perkins.com

Reference Information

Section

NOTICE

Dependant upon engine type and application.

Reference Materials

i06103116

i07677995

Decommissioning and

Reference Material

Disposal

(Extended Service Contract)

When the product is removed from service, local

regulations for the product decommissioning will

Extended Service Contracts - purchased in minutes,

vary. Disposal of the product will vary with local

protected for years.

regulations. Consult the nearest Perkins distributor

for additional information.

Extended Service Contracts (ESC) protect you from

the stress that unexpected repair work brings to your

i05204672

life by covering the cost of getting your engine up and

running again. Unlike other extended warranties,

Maintenance Records

Perkins Platinum ESC protects you against all

component part failures.

Purchase peace of mind from only £0.03 / $0.05 /

Perkins recommends the retention of accurate

euro 0.04 a day and let an ESC make your dreams a

maintenance records. Accurate maintenance records

reality.

can be used for the following purposes:

Why buy an Extended Service Contract?

• Determine operating costs.

1. No surprises - total protection from unexpected

• Establish maintenance schedules for other

repair cost (parts, labor, and travel).

engines that are operated in the same

environment.

2. Enjoy longer lasting product support from Perkins

global network.

• Show compliance with the required maintenance

practices and maintenance intervals.

3. Genuine Perkins parts ensure continued engine

performance.

Maintenance records can be used for various other

business decisions that are related to engine

4. Highly trained technicians carry out all repairs.

maintenance.

5. Transferable coverage should you sell your

Maintenance records are a key element of a

machine.

maintenance program that is correctly managed.

Accurate maintenance records can help your Perkins

Flexible coverage provides the right level of

dealer to fine-tune the recommended maintenance

protection for your Perkins Engine. Coverage can be

intervals in order to meet the specific operating

extended to 2 years/ 1,000 hours right up to 10 year/

situation. This should result in a lower engine

40,000

operating cost.

You can buy an ESC at any time during standard

Records should be kept for the following items:

warranty - even the last day!

Fuel Consumption - A record of fuel consumption is

Each Perkins Distributor has highly trained and

essential in order to determine when the load

experienced Perkins Product Support Service

sensitive components should be inspected or

Technicians. The Support Service is equipped, and

repaired. Fuel consumption also determines overhaul

available around the clock to get your engine running

intervals.

again with the minimum of downtime. Buying an ESC

means that you get all this for free.

Service Hours - A record of service hours is

essential to determine when the speed sensitive

To purchase an Extended Service Contract, is quick

components should be inspected or repaired.

and simple! Contact your local Perkins Distributor

Documents - These items should be easy to obtain,

now and the distributor can provide you with a quote

and these items should be kept in the engine history

in minutes. You can locate your nearest Perkins

file. All of the documents should show this

Distributor by visiting:

information: date, service hours, fuel consumption,

M0076814-03

115

Index Section

Index

Flush

Cooling System Coolant Extender (ELC) -

Additional Messages

Add

After Starting Engine

Cooling System Coolant Level - Check

Extended Idle at Cold Ambient

Cooling System Supplemental Coolant

Temperature

Additive (SCA) - Test/Add

After Stopping Engine

Add the SCA, If Necessary

Air Compressor - Check (If Equipped)

Test for SCA Concentration

Air Tank Moisture and Sediment - Drain (If

Crushing Prevention and Cutting Prevention.. 15

Equipped)

ARD Spark Plug (Emission Related

Component) - Clean

Installing the Spark Plug

Decommissioning and Disposal

112

Removing the Spark Plug

DEF Filler Screen (Emission Related

Component) - Clean

DEF Manifold Filters (Emission Related

Component) - Replace

Battery - Recycle

Type 1 Manifold

Battery - Replace

Type 2 Manifold

Battery Disconnect Switch (If Equipped)

Diesel Exhaust Fluid (Emission Related

Battery Electrolyte Level - Check

Component) - Fill

Battery or Battery Cable - Disconnect

Diesel Exhaust Fluid Filter (Emission

Before Starting Engine

15, 44

Related Component) - Replace

Belts - Inspect/Adjust/Replace (Vee Belt

Diesel Exhaust Fluid Injector (Emission

General Information)

Related Component) - Replace

Alternator Belt and Fan Belt

Diesel Particulate Filter (Emission Related

Belt Tension

Component) - Clean

Belts - Inspect/Replace (General

Diesel Particulate Filter Regeneration

Information for Poly Vee Belts)

Carbon Dioxide (CO₂) Emissions

Inspect

Statement

Replace

Modes of Regeneration

Burn Prevention

Regeneration

Batteries

Regeneration Indicators

Coolant

Regeneration Switch

Diesel Fuel

Regeneration System Warning Indicators... 50

Engine and Aftertreatment System

Regeneration Triggers

Oils

Driven Equipment - Check

Cold Weather Operation

Electrical System

Cold Weather Starting

Grounding Practices

Ether Injection System (If Equipped)

Emissions Certification Film

Cooling System Coolant (DEAC) - Change

Emissions Warranty Information

111

Drain

Engaging the Driven Equipment

Fill

Engine - Clean

Flush

Aftertreatment

Cooling System Coolant (ELC) - Change

Engine Air Cleaner Element - Replace

Drain

Dual Element Air Cleaner

Fill

116

M0076814-03

Index Section

Servicing the Air Cleaner Element

California Proposition 65 Warning

Engine Air Cleaner Service Indicator -

Literature Information

Inspect (If Equipped)

Maintenance

Test the Service Indicator

Maintenance Intervals

Engine Diagnostics

Operation

Engine Electronics

Overhaul

Engine Mounts - Inspect

Safety

Engine Oil and Filter - Change

Fuel and the Effect from Cold Weather

Drain the Engine Lubricating Oil

Fuel Conservation Practices

Fill the Oil Pan

Fuel Related Components in Cold Weather ... 55

Oil and Filter Change Intervals

Fuel Heaters

Engine Oil Level - Check

Fuel Tanks

Engine Oil Sample - Obtain

Fuel System - Prime

103

Obtain the Sample and the Analysis

Fuel System Primary Filter (Water

Engine Operation

Separator) Element - Replace

104

Engine Operation and the Aftertreatment

Fuel System Primary Filter/Water

System

Separator - Drain

105

Engine Starting

16, 44

Fuel System Secondary Filter - Replace

105

Engine Stopping

16, 53

Fuel Tank Water and Sediment - Drain

106

Engine Storage Procedure - Check

100

Drain the Water and the Sediment

106

Additional Information

103

Fuel Storage Tanks

107

Aftertreatment

101

Fuel Tank

106

Coolant System

101

Engine

100

Remove Aftertreatment from Storage

102

General Hazard Information

Remove Engine from Storage

101

Containing Fluid Spillage

Removing Application from Storage

101

Diesel Exhaust Fluid

Special Precautions

100

Dispose of Waste Properly

Engine Valve Lash - Check

103

Fluid Penetration

Inhalation

Pressurized Air and Water

Fault Logging

Static Electricity Hazard when Fueling with

Features and Controls

Ultra-low Sulfur Diesel Fuel

Fire Prevention and Explosion Prevention

Grounding Stud - Inspect/Clean/Tighten

107

Ether

Fire Extinguisher

Lines, Tubes, and Hoses

Hoses and Clamps - Inspect/Replace

107

Fluid Recommendations

65, 69

Fuel System

108

ELC Cooling System Maintenance

Replace the Hoses and the Clamps

108

Engine Oil

General Coolant Information

General Lubricant Information

Fluid Recommendations (General Fuel

Important Safety Information

Information)

Contamination Control Recommendations for

Fuels

Diesel Fuel Characteristics

Lifting and Storage

Diesel Fuel Requirements

General Information

Foreword

Maintenance Interval Schedule

M0076814-03

117

Index Section

Daily

Pump Electronic Tank Unit (PETU)

Every 10 000 Service Hours

Radiator Only

Every 12 000 Service Hours or 6 Years

Product Storage (Engine and

Every 250 Service Hours

Aftertreatment)

Every 2500 Service Hours

Condition for Storage

Every 3000 Service Hours or 3 Years

Every 4000 Service Hours

Every 500 Service Hours

Radiator - Clean

109

Every 500 Service Hours or 3 Months

Radiator Restrictions

Every 5000 Service Hours

Reference Information Section

112

Every 585 000 L (154 540 US gal) of Fuel or

Reference Material (Extended Service

10 000 Service Hours

Contract)

112

Every 6000 Service Hours or 3 Years

Reference Materials

112

Initial 500 Service Hours

Refill Capacities

When Required

Refill Capacities and Recommendations

Maintenance Log

113

Recommendation

Maintenance Recommendations

Refill Capacities

Maintenance Records

112

Maintenance Section

Manual Stop Procedure

Model View Illustrations

Safety Messages

Aftertreatment System

Sulfuric Acid Burn (2)

Clean Emission Module

Universal Warning (1)

Engine Views

Safety Section

Model Views

Selective Catalytic Reduction Warning

Monitoring System

System

Monitoring System Indicators

Definitions

Mounting and Dismounting

Inducement Strategy for DEF Level

(European Union)

Inducement Strategy for DEF Level

(Worldwide)

Operation Section

Inducement Strategy for Escalating Time

Overhaul Considerations

108

Inducement Faults (European Union)

Inducement Strategy for Escalating Time

Inducement Faults (Worldwide)

Plate Locations and Film Locations

Self-Diagnostics

Pump Electronic Tank Unit (PETU) and Pump

Sensors and Electrical Components

Electronic Unit (PEU)

Aftertreatment System

Power Take-Off Clutch - Check

108

Engine

Product Description

Pump Electronic Tank Unit (PETU)

Aftermarket Products and Perkins

Severe Service Application

Engines

Environmental Factors

Electronic Engine Features

Incorrect Maintenance Procedures

Engine Diagnostics

Incorrect Operating Procedures

Engine Service Life

Starting Motor - Inspect

109

Engine Specifications

Starting the Engine

Product Identification Information

Problems with the Wiring Harness

Product Information Section

Starting Problems

Product Lifting

Starting the Engine

Clean Emission Module (CEM) Lifting

Starting with Jump Start Cables (Do Not

Engine Lifting

Use This Procedure in Hazardous