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September 2007
Operation and
Maintenance
Manual
400C Industrial Engine
HB (Engine)
HD (Engine)
HH (Engine)
HL (Engine)
HM (Engine)
HN (Engine)
HP (Engine)
HR (Engine)
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Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
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SEBU7992-02 3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 5
Operation Section
Lifting and Storage ................................................ 23
Maintenance Section
Refill Capacities .................................................... 37
Warranty Section
Warranty Information ............................................ 77
Index Section
Index ..................................................................... 78
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4 SEBU7992-02
Foreword
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SEBU7992-02 5
Safety Section
Safety Messages
Safety Section The warning labels that may be found on the engine
are illustrated and described.
i02810656
Ether (1)
Safety Messages The warning label for ether is located on the front,
left side of the valve mechanism cover for all engine
models in the series.
g00640926
g01131697
Illustration 1 i02328435
Typical example
General Hazard Information
There may be several specific safety messages on
an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiar with all warning
signs.
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6 SEBU7992-02
Safety Section
General Hazard Information
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
Illustration 3
g00702020 cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Wear a hard hat, protective glasses, and other
protective equipment, as required. Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
Do not wear loose clothing or jewelry that can snag may occur. Do not disassemble any hydraulic
on controls or on other parts of the engine. components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
Make sure that all protective guards and all covers information for any procedures that are required to
are secured in place on the engine. relieve the hydraulic pressure.
Ensure that the power supply is disconnected before Always use a board or cardboard when you check
you work on the bus bar or the glow plugs. for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
Perform maintenance on the engine with the serious injury and possible death. A pin hole leak can
equipment in the servicing position. Refer to the cause severe injury. If fluid is injected into your skin,
OEM information for the procedure for placing the you must get treatment immediately. Seek treatment
equipment in the servicing position. from a doctor that is familiar with this type of injury.
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SEBU7992-02 7
Safety Section
Burn Prevention
Only use the tools that are suitable for containing i02813488
fluids and equipment that is suitable for containing
fluids. Fire Prevention and Explosion
Prevention
Obey all local regulations for the disposal of liquids.
i02143195
Burn Prevention
Coolant Illustration 5
g00704000
When the engine is at operating temperature, the All fuels, most lubricants, and some coolant mixtures
engine coolant is hot. The coolant is also under are flammable.
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
Any contact with hot coolant or with steam can cause a fire. Fire may cause personal injury and property
severe burns. Allow cooling system components to damage.
cool before the cooling system is drained.
A flash fire may result if the covers for the engine
Check the coolant level after the engine has stopped crankcase are removed within fifteen minutes after
and the engine has been allowed to cool. an emergency shutdown.
Ensure that the filler cap is cool before removing the Determine whether the engine will be operated in an
filler cap. The filler cap must be cool enough to touch environment that allows combustible gases to be
with a bare hand. Remove the filler cap slowly in drawn into the air inlet system. These gases could
order to relieve pressure. cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact If the application involves the presence of combustible
the skin, the eyes, or the mouth. gases, consult your Perkins dealer and/or your
Perkins distributor for additional information about
Oils suitable protection devices.
Hot oil and hot lubricating components can cause Remove all flammable combustible materials or
personal injury. Do not allow hot oil to contact the conductive materials such as fuel, oil, and debris from
skin. Also, do not allow hot components to contact the engine. Do not allow any flammable combustible
the skin. materials or conductive materials to accumulate on
the engine.
Batteries Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
Electrolyte is an acid. Electrolyte can cause personal oily rags and any flammable materials in protective
injury. Do not allow electrolyte to contact the skin or containers. Do not smoke in areas that are used for
the eyes. Always wear protective glasses for servicing storing flammable materials.
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended. Do not expose the engine to any flame.
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8 SEBU7992-02
Safety Section
Fire Prevention and Explosion Prevention
Exhaust shields (if equipped) protect hot exhaust Use caution when you are refueling an engine. Do
components from oil or fuel spray in case of a line, not smoke while you are refueling an engine. Do not
a tube, or a seal failure. Exhaust shields must be refuel an engine near open flames or sparks. Always
installed correctly. stop the engine before refueling.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
g00704059
Illustration 6
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SEBU7992-02 9
Safety Section
Crushing Prevention and Cutting Prevention
Lines, Tubes and Hoses When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent Chips or other debris may fly off objects when objects
or damaged. Do not clip any other items to the high are struck. Before objects are struck, ensure that no
pressure lines. one will be injured by flying debris.
Crushing Prevention and Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
Cutting Prevention provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
Support the component correctly when work beneath See the Service Manual for repairs and for
the component is performed.
adjustments.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is i02157354
running.
Engine Starting
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan Do not use aerosol types of starting aids such as
blades will throw objects or cut objects. ether. Such use could result in an explosion and
personal injury.
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10 SEBU7992-02
Safety Section
Engine Stopping
If a warning tag is attached to the engine start switch Use the Emergency Stop Button (if equipped)
or to the controls, DO NOT start the engine or move ONLY in an emergency situation. DO NOT use the
the controls. Consult with the person that attached Emergency Stop Button for normal engine stopping.
the warning tag before the engine is started. After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
All protective guards and all protective covers must has been corrected.
be installed if the engine must be started in order
to perform service procedures. To help prevent an On the initial start-up of a new engine or an engine
accident that is caused by parts in rotation, work that has been serviced, make provisions to stop the
around the parts carefully. engine if an overspeed condition occurs. This may be
accomplished by shutting off the fuel supply and/or
Start the engine from the operators compartment or the air supply to the engine.
from the engine start switch.
If equipped, in order to stop an electronically
Always start the engine according to the procedure controlled engine, cut the power to the engine.
that is described in the Operation and Maintenance
Manual, Engine Starting topic in the Operation
i02176668
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
Electrical System
personal injury.
To ensure that the jacket water heater (if equipped) Never disconnect any charging unit circuit or battery
and/or the lube oil heater (if equipped) is working circuit cable from the battery when the charging unit
correctly, check the water temperature gauge and the is operating. A spark can cause the combustible
oil temperature gauge during the heater operation. gases that are produced by some batteries to ignite.
Engine exhaust contains products of combustion To help prevent sparks from igniting combustible
which can be harmful to your health. Always start the gases that are produced by some batteries, the
engine and operate the engine in a well ventilated negative jump start cable should be connected
area. If the engine is started in an enclosed area, last from the external power source to the negative
vent the engine exhaust to the outside. terminal of the starting motor. If the starting motor
is not equipped with a negative terminal, connect
Note: The engine is equipped with an automatic the jump start cable to the engine block.
device for cold starting for normal conditions of
operation. If the engine will be operated in very cold Check the electrical wires daily for wires that are
conditions, then an extra cold starting aid may be loose or frayed. Tighten all loose electrical wires
required. Normally, the engine will be equipped with before the engine is started. Repair all frayed
the correct type of starting aid for your region of electrical wires before the engine is started. See
operation. the Operation and Maintenance Manual for specific
starting instructions.
The 400 Series engines are equipped with a glow
plug starting aid in each individual cylinder that heats
the intake air in order to improve starting. Grounding Practices
Correct grounding for the engine electrical system
i02590389 is necessary for optimum engine performance
and reliability. Incorrect grounding will result in
Engine Stopping uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
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SEBU7992-02 11
Safety Section
Electrical System
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12 SEBU7992-02
Product Information Section
Model Views
Product Information
Section
Model Views
i02810676
g01109207
Illustration 8
Typical view of the 402C-05 engine
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SEBU7992-02 13
Product Information Section
Model Views
g01109212
Illustration 9
Typical view of the 403C-11 engine
g01402021
Illustration 10
Typical view of the 403C-17 engine
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14 SEBU7992-02
Product Information Section
Model Views
g01097209
Illustration 11
Front and left side view of the 404C-22T Engine
(1) Engine oil filler cap (7) Exhaust manifold (13) Engine oil drain plug
(2) Coolant temperature switch (8) Turbocharger (14) Engine oil pan
(3) Crankcase breather (9) Starting motor solenoid (15) Crankshaft pulley
(4) Valve mechanism cover (10) Electric starting motor (16) Cover plate for the accessory drive
(5) Lifting eye (11) Alternator (17) Cooling fan
(6) Water temperature regulator housing (12) Fan drive belt (18) Water pump
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SEBU7992-02 15
Product Information Section
Model Views
g01097214
Illustration 12
Rear and right side view of the 404C-22T Engine
(19) Fuel injector (24) Fuel injection pump (29) Flywheel
(20) Fuel return line (25) Fuel control lever (30) Flywheel housing
(21) Lifting eye (26) Engine oil level gauge (31) Fuel transfer pump
(22) Fuel injection lines (27) Engine oil filter (32) Fuel shutoff solenoid
(23) Mechanical fuel shutoff (28) Engine oil cooler (33) Air inlet elbow
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16 SEBU7992-02
Product Information Section
Model Views
The timing gears are stamped with timing marks in Engine Specifications
order to ensure the correct assembly of the gears.
When the No. 1 piston is at top center compression Note: The front end of the engine is opposite the
stroke, the teeth that are stamped on the crankshaft flywheel end of the engine. The left and the right side
gear and the camshaft gear will be in alignment with of the engine are determined from the flywheel end.
the idler gear. The No. 1 cylinder is the front cylinder.
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SEBU7992-02 17
Product Information Section
Model Views
g01108476 g00852304
Illustration 13 Illustration 14
(A) Exhaust valves (A) Exhaust valves
(B) Inlet valves (B) Inlet valves
Table 1 Table 2
402C-05 Engine Specifications 403C-07 Engine Specifications
Maximum Operating Maximum Operating
3600 rpm 3600 rpm
Speed (rpm) Speed (rpm)
Cylinders and Cylinders and
In-Line two cylinder In-Line three cylinder
Arrangement Arrangement
Bore 67 mm (2.64 inch) Bore 67 mm (2.64 inch)
Stroke 72 mm (2.83 inch) Stroke 72 mm (2.83 inch)
Displacement 0.507 L (30.939 in )
3
Displacement 0.762 L (46.500 in3)
Aspiration NA(1) Aspiration NA(1)
Compression Ratio 23.5:1 Compression Ratio 23.5:1
Firing Order 1-2 Firing Order 1-2-3
Rotation that is viewed Rotation that is viewed
Counterclockwise Counterclockwise
from the flywheel from the flywheel
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting Valve Lash Setting
0.20 mm (0.008 inch) 0.20 mm (0.008 inch)
(Exhaust) (Exhaust)
(1) Naturally Aspirated (1) Naturally Aspirated
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18 SEBU7992-02
Product Information Section
Model Views
g00852304 g00852304
Illustration 15 Illustration 16
(A) Exhaust valves (A) Exhaust valves
(B) Inlet valves (B) Inlet valves
Table 3 Table 4
403C-11 Engine Specifications 403C-15 Engine Specifications
Maximum Operating Maximum Operating
3600 rpm 3000 rpm
Speed (rpm) Speed (rpm)
Cylinders and Cylinders and
In-Line three cylinder In-Line three cylinder
Arrangement Arrangement
Bore 77 mm (3.03 inch) Bore 84 mm (3.31 inch)
Stroke 81 mm (3.19 inch) Stroke 90 mm (3.54 inch)
Displacement 1.131 L (69.018 in )
3
Displacement 1.496 L (91.291 in3)
Aspiration NA(1) Aspiration NA(1)
Compression Ratio 23:1 Compression Ratio 22.5:1
Firing Order 1-2-3 Firing Order 1-2-3
Rotation that is viewed Rotation that is viewed
Counterclockwise Counterclockwise
from the flywheel from the flywheel
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting Valve Lash Setting
0.20 mm (0.008 inch) 0.20 mm (0.008 inch)
(Exhaust) (Exhaust)
(1) Naturally Aspirated (1) Naturally Aspirated
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SEBU7992-02 19
Product Information Section
Model Views
g00852304 g00296424
Illustration 17 Illustration 18
(A) Exhaust valves (A) Exhaust valves
(B) Inlet valves (B) Inlet valves
Table 5 Table 6
403C-17 Engine Specifications 404C-15 Engine Specifications
Maximum Operating Maximum Operating
2600 rpm 3000 rpm
Speed (rpm) Speed (rpm)
Cylinders and Cylinders and
In-Line three cylinder In-Line four cylinder
Arrangement Arrangement
Bore 84 mm (3.31 inch) Bore 77 mm (3.03 inch)
Stroke 100 mm (3.94 inch) Stroke 81 mm (3.19 inch)
Displacement 1.66 L (101.3 in )
3
Displacement 1.508 L (92.024 in3)
Aspiration NA(1) Aspiration NA(1)
Compression Ratio 22.5:1 Compression Ratio 23.5:1
Firing Order 1-2-3 Firing Order 1-3-4-2
Rotation that is viewed Rotation that is viewed
Counterclockwise Counterclockwise
from the flywheel from the flywheel
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting Valve Lash Setting
0.20 mm (0.008 inch) 0.20 mm (0.008 inch)
(Exhaust) (Exhaust)
(1) Naturally Aspirated (1) Naturally Aspirated
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20 SEBU7992-02
Product Information Section
Model Views
g00296424 g00296424
Illustration 19 Illustration 20
(A) Exhaust valves (A) Exhaust valves
(B) Inlet valves (B) Inlet valves
Table 7 Table 8
404C-22 Engine Specifications 404C-22T Engine Specifications
Maximum Operating Maximum Operating
3000 rpm 3000 rpm
Speed (rpm) Speed (rpm)
Cylinders and Cylinders and
In-Line four cylinder In-Line four cylinder
Arrangement Arrangement
Bore 84.0 mm (3.31 inch) Bore 84.0 mm (3.31 inch)
Stroke 100.0 mm (3.94 inch) Stroke 100.0 mm (3.94 inch)
Displacement 2.216 L (135.229 in )
3
Displacement 2.216 L (135.229 in3)
Aspiration NA(1) Aspiration T(1)
Compression Ratio 23.3:1 Compression Ratio 23.3:1
Firing Order 1-3-4-2 Firing Order 1-3-4-2
Rotation that is viewed Rotation that is viewed
Counterclockwise Counterclockwise
from the flywheel from the flywheel
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting Valve Lash Setting
0.20 mm (0.008 inch) 0.20 mm (0.008 inch)
(Exhaust) (Exhaust)
(1) Naturally Aspirated (1) Turbocharged
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SEBU7992-02 21
Product Information Section
Product Identification Information
i02216958 i02164876
Perkins engines are identified by a serial number. Information for the following items may be needed to
This number is shown on a serial number plate that order parts. Locate the information for your engine.
is mounted above the fuel injection pump on the right Record the information in the appropriate space.
hand side of the engine block. Make a copy of this list for a record. Keep the
information for future reference.
An example of an engine number is HHU000001J.
HH _________________________________________Type of engine
Record for Reference
Engine Model _______________________________________________
U ____________________________Built in the United Kingdom
Engine Serial number _____________________________________
Engines that are built in Japan will have a (J).
Engine Low Idle rpm ______________________________________
Engines that are built in North America will have a
(N). Engine Full Load rpm _____________________________________
000001 ___________________________Engine Serial Number Primary Fuel Filter _________________________________________
J _____________________________________Year of Manufacture Water Separator Element ________________________________
Perkins dealers or Perkins distributors need all of Secondary Fuel Filter Element __________________________
these numbers in order to determine the components
that were included with the engine. This permits Lubrication Oil Filter Element ___________________________
accurate identification of replacement part numbers.
Auxiliary Oil Filter Element _______________________________
i02157258
Total Lubrication System Capacity _____________________
Serial Number Plate
Total Cooling System Capacity _________________________
i02166528
g01094203
Illustration 21
Typical serial number plate
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22 SEBU7992-02
Product Information Section
Product Identification Information
g01098670
Illustration 22
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SEBU7992-02 23
Operation Section
Lifting and Storage
i02134814
Engine Storage
Lubrication System
To help prevent excessive engine wear, use the
following guidelines:
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24 SEBU7992-02
Operation Section
Lifting and Storage
Renew the canister(s) of the lubricating oil filter. 1. Ensure that the vehicle is on level ground.
Fill the oil pan to the Full Mark on the engine oil 2. Remove the filler cap of the cooling system.
level gauge with new, clean lubricating oil. Add
1762811 POWERPART Lay-Up 2 to the oil in 3. Remove the drain plug (1) from the side of the
order to protect the engine against corrosion. If cylinder block in order to drain the engine. Ensure
1762811 POWERPART Lay-Up 2 is not available, that the drain hole is not restricted.
use a preservative of the correct specification
instead of the lubricating oil. If a preservative is 4. Open the tap or remove the drain plug at the
used, this must be drained completely at the end of bottom of the radiator in order to drain the radiator.
the storage period and the oil pan must be refilled If the radiator does not have a tap or a drain plug,
to the correct level with normal lubricating oil. disconnect the hose at the bottom of the radiator.
Induction System
Remove the air filter assembly. If necessary,
remove the pipes that are installed between
the air filter assembly and the turbocharger.
Spray 1762811 POWERPART Lay-Up 2 into the
turbocharger. The duration of the spray is printed
on the container. Seal the turbocharger with
waterproof tape.
g01087295
Illustration 24
Typical example
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SEBU7992-02 25
Operation Section
Lifting and Storage
Exhaust System
Remove the exhaust pipe. Spray 1762811
POWERPART Lay-Up 2 into the turbocharger. The
duration of the spray is printed on the container.
Seal the turbocharger with waterproof tape.
General Items
If the lubricating oil filler is installed on the valve
mechanism cover, remove the filler cap. If the
lubricating oil filler cap is not installed on the valve
mechanism cover, remove the valve mechanism
cover. Spray 1762811 POWERPART Lay-Up 2
around the rocker shaft assembly. Replace the
filler cap or the valve mechanism cover.
Seal the vent of the fuel tank or the fuel filler cap
with waterproof tape.
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26 SEBU7992-02
Operation Section
Gauges and Indicators
Gauges and Indicators 1. Reduce the load and the engine rpm.
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SEBU7992-02 27
Operation Section
Features and Controls
Fuel Shutoff
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28 SEBU7992-02
Operation Section
Engine Starting
Engine Starting Do not start the engine or move any of the controls
if there is a DO NOT OPERATE warning tag or
similar warning tag attached to the start switch or
i02194223 to the controls.
Before Starting Engine Ensure that the areas around the rotating parts are
clear.
Inspect the alternator and accessory drive belts for Check the coolant level. Observe the coolant level
cracks, breaks, and other damage. in the header tank (if equipped). Maintain the
coolant level to the FULL mark on the header
Inspect the wiring for loose connections and for tank.
worn wires or frayed wires.
If the engine is not equipped with a header tank
Check the fuel supply. Drain water from the water maintain the coolant level within 13 mm (0.5 inch)
separator (if equipped). Open the fuel supply valve of the bottom of the filler pipe. If the engine is
(if equipped). equipped with a sight glass, maintain the coolant
level in the sight glass.
NOTICE
All valves in the fuel return line must be open before Observe the air cleaner service indicator (if
and during engine operation to help prevent high fuel equipped). Service the air cleaner when the yellow
pressure. High fuel pressure may cause filter housing diaphragm enters the red zone, or when the red
failure or other damage. piston locks in the visible position.
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SEBU7992-02 29
Operation Section
Engine Starting
NOTICE
Do not operate the glow plugs for more than 30 sec-
onds at one time. Damage to the glow plugs could oc-
cur. Improper jump start cable connections can cause
an explosion resulting in personal injury.
2. Turn the engine start switch to the HEAT position.
Hold the engine start switch in the HEAT position Prevent sparks near the batteries. Sparks could
for 6 seconds until the glow plug indicator light cause vapors to explode. Do not allow jump start
illuminates. This will activate the glow plugs and cable ends to contact each other or the engine.
aid in the starting of the engine.
Note: If it is possible, first diagnose the reason
NOTICE for the starting failure. Make any necessary
Do not crank the engine for more than 30 seconds. repairs. If the engine will not start only due to
Allow the electric starting motor to cool for two minutes the condition of the battery, either charge the
before cranking the engine again. battery, or start the engine with jump start cables.
The condition of the battery can be rechecked
after the engine has been switched OFF.
3. While the glow plug indicator light is illuminated,
turn the engine start switch to the START position
and crank the engine.
NOTICE
4. When the engine starts, release the engine start Using a battery source with the same voltage as the
switch. electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
5. Slowly move the throttle lever to the low idle the electrical system.
position and allow the engine to idle. Refer to
the Operation and Maintenance Manual, After Do not reverse the battery cables. The alternator can
Starting Engine topic. be damaged. Attach ground cable last and remove
first.
Note: If the glow plug indicator light illuminates
rapidly for 2 to 3 seconds, or if the glow plug indicator When using an external electrical source to start the
light fails to illuminate, a malfunction exists in the cold engine, turn the generator set control switch to the
start system. Do not use ether or other starting fluids OFF position. Turn all electrical accessories OFF be-
to start the engine. fore attaching the jump start cables.
6. If the engine does not start, release the engine Ensure that the main power switch is in the OFF posi-
start switch and allow the electric starting motor to tion before attaching the jump start cables to the en-
cool. Then, repeat steps 2 through step 5. gine being started.
7. Turn the engine start switch to the OFF position in 1. Turn the start switch to the OFF position. Turn off
order to stop the engine. all the engines accessories.
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30 SEBU7992-02
Operation Section
Engine Starting
i01903609
Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
possible in some applications.
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SEBU7992-02 31
Operation Section
Engine Operation
Engine Operation
The efficiency of the engine can affect the fuel
economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
Correct operation and maintenance are key factors all applications. Follow the recommended procedures
in obtaining the maximum life and economy of in order to attain optimum performance for the life
the engine. If the directions in the Operation and of the engine.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. Avoid spilling fuel.
The engine can be operated at the rated rpm after the Fuel expands when the fuel is warmed up. The fuel
engine reaches operating temperature. The engine may overflow from the fuel tank. Inspect fuel lines for
will reach normal operating temperature sooner leaks. Repair the fuel lines, as needed.
during a low engine speed (rpm) and during a low
power demand. This procedure is more effective than Be aware of the properties of the different fuels.
idling the engine at no load. The engine should reach Use only the recommended fuels.
operating temperature in a few minutes.
Avoid unnecessary idling.
Gauge readings should be observed and the data
should be recorded frequently while the engine Shut off the engine rather than idle for long periods of
is operating. Comparing the data over time will time.
help to determine normal readings for each gauge.
Comparing data over time will also help detect Observe the air cleaner service indicator frequently.
abnormal operating developments. Significant Keep the air cleaner elements clean.
changes in the readings should be investigated.
Maintain the electrical systems.
One damaged battery cell will overwork the alternator.
This will consume excess power and excess fuel.
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32 SEBU7992-02
Operation Section
Engine Stopping
Avoid accelerating the engine prior to shutting it down. If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.
Avoiding hot engine shutdowns will maximize tur-
bocharger shaft and bearing life. If the engine is equipped with a service hour meter,
note the reading. Perform the maintenance that
is in the Operation and Maintenance Manual,
Note: Individual applications will have different Maintenance Interval Schedule.
control systems. Ensure that the shutoff procedures
are understood. Use the following general guidelines Fill the fuel tank in order to help prevent
in order to stop the engine. accumulation of moisture in the fuel. Do not overfill
the fuel tank.
1. Remove the load from the engine. Reduce the
engine speed (rpm) to low idle. Allow the engine NOTICE
to idle for five minutes in order to cool the engine. Only use antifreeze/coolant mixtures recommended in
the Coolant Specifications that are in the Operation
2. Stop the engine after the cool down period and Maintenance Manual. Failure to do so can cause
according to the shutoff system on the engine and engine damage.
turn the ignition key switch to the OFF position.
If necessary, refer to the instructions that are
provided by the OEM. Allow the engine to cool. Check the coolant level.
If freezing temperatures are expected, check
i01903586 the coolant for correct antifreeze protection. The
cooling system must be protected against freezing
Emergency Stopping to the lowest expected outside temperature. Add
the correct coolant/water mixture, if necessary.
This document has been printed from SPI. Not for Resale
SEBU7992-02 33
Operation Section
Cold Weather Operation
i02717265 Check all rubber parts (hoses, fan drive belts, etc)
weekly.
Cold Weather Operation
Check all electrical wiring and connections for any
fraying or damaged insulation.
Perkins Diesel Engines can operate effectively in Keep all batteries fully charged and warm.
cold weather. During cold weather, the starting and
the operation of the diesel engine is dependent on Fill the fuel tank at the end of each shift.
the following items:
Check the air cleaners and the air intake daily.
The type of fuel that is used Check the air intake more often when you operate
in snow.
The viscosity of the engine oil
Ensure that the glow plugs are in working order.
The operation of the glow plugs Refer to Testing and Adjusting Manual, Glow Plug
- Test.
Optional Cold starting aid
Battery condition
This section will cover the following information: Personal injury or property damage can result
from alcohol or starting fluids.
Potential problems that are caused by cold weather Alcohol or starting fluids are highly flammable and
operation
toxic and if improperly stored could result in injury
or property damage.
Suggest steps which can be taken in order to
minimize starting problems and operating problems
when the ambient air temperature is between
0 to40 C (32 to 40 F).
The operation and maintenance of an engine in Do not use aerosol types of starting aids such as
freezing temperatures is complex . This is because ether. Such use could result in an explosion and
of the following conditions: personal injury.
This document has been printed from SPI. Not for Resale
34 SEBU7992-02
Operation Section
Cold Weather Operation
In cold weather, check the coolant often for the Free operation of the valves is prevented.
correct glycol concentration in order to ensure
adequate freeze protection. Valves become stuck.
Engine Block Heaters Pushrods may become bent.
Engine block heaters (if equipped) heat the Other damage to valve train components can
engine jacket water that surrounds the combustion result.
chambers. This provides the following functions:
For this reason, when the engine is started,
Startability is improved. the engine must be operated until the coolant
temperature is 71 C (160 F) minimum. Carbon
Warm up time is reduced. deposits on the valve stems will be kept at a minimum
and the free operation of the valves and the valve
An electric block heater can be activated once components will be maintained.
the engine is stopped. An effective block heater
is typically a 1250/1500 W unit. Consult your In addition, the engine must be thoroughly warmed in
Perkins dealer or your Perkins distributor for more order to keep other engine parts in better condition
information. and the service life of the engine will be generally
extended. Lubrication will be improved. There will be
less acid and less sludge in the oil. This will provide
Idling the Engine longer service life for the engine bearings, the piston
rings, and other parts. However, limit unnecessary
When idling after the engine is started in cold idle time to ten minutes in order to reduce wear and
weather, increase the engine rpm from 1000 to 1200 unnecessary fuel consumption.
rpm. This will warm up the engine more quickly.
Maintaining an elevated low idle speed for extended
periods will be easier with the installation of a hand
The Water Temperature Regulator and
throttle. The engine should not be raced in order to Insulated Heater Lines
speed up the warm up process.
The engine is equipped with a water temperature
While the engine is idling, the application of a light regulator. When the engine coolant is below the
load (parasitic load) will assist in achieving the correct operating temperature jacket water circulates
minimum operating temperature. The minimum through the engine cylinder block and into the
operating temperature is 82 C (179.6 F). engine cylinder head. The coolant then returns to the
cylinder block via an internal passage that bypasses
the valve of the coolant temperature regulator. This
Recommendations for Coolant ensures that coolant flows around the engine under
Warm Up cold operating conditions. The water temperature
regulator begins to open when the engine jacket
Warm up an engine that has cooled below normal water has reached the correct minimum operating
operating temperatures due to inactivity. This should temperature. As the jacket water coolant temperature
be performed before the engine is returned to full rises above the minimum operating temperature the
operation. During operation in very cold temperature water temperature regulator opens further allowing
conditions, damage to engine valve mechanisms can more coolant through the radiator to dissipate excess
result from engine operation for short intervals. This heat.
can happen if the engine is started and the engine is
stopped many times without being operated in order The progressive opening of the water temperature
to warm up completely. regulator operates the progressive closing of the
bypass passage between the cylinder block and
When the engine is operated below normal operating head. This ensures maximum coolant flow to
temperatures, fuel and oil are not completely burned the radiator in order to achieve maximum heat
in the combustion chamber. This fuel and oil causes dissipation.
soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and Note: Perkins discourages the use of all air flow
the deposits are burned off during operation at restriction devices such as radiator shutters.
normal engine operating temperatures. Restriction of the air flow can result in the following:
high exhaust temperatures, power loss, excessive
When the engine is started and the engine is stopped fan usage, and reduction in fuel economy.
many times without being operated in order to warm
up completely, the carbon deposits become thicker.
This can cause the following problems:
This document has been printed from SPI. Not for Resale
SEBU7992-02 35
Operation Section
Cold Weather Operation
A cab heater is beneficial in very cold weather. The When Group 2 diesel fuels are used the following
feed from the engine and the return lines from the components provide a means of minimizing problems
cab should be insulated in order to reduce heat loss in cold weather:
to the outside air.
Glow plugs (if equipped)
Insulating the Air Inlet and Engine
Compartment Engine coolant heaters, which may be an OEM
option
When temperatures below 18 C (0 F) will be
frequently encountered, an air cleaner inlet that Fuel heaters, which may be an OEM option
is located in the engine compartment may be
specified. An air cleaner that is located in the engine Fuel line insulation, which may be an OEM option
compartment may also minimize the entry of snow
There are three major differences between Group
into the air cleaner. Also, heat that is rejected by the
1 fuels and Group 2 fuels. Group 1 fuels have the
engine helps to warm the intake air.
following different characteristics to Group 2 fuels.
Additional heat can be retained around the engine by
insulating the engine compartment. A lower cloud point
A lower pour point
i02322217
A higher energy per unit volume of fuel
Fuel and the Effect from Cold
Weather Note: Group 3 fuels reduce the life of the engine. The
use of Group 3 fuels is not covered by the Perkins
warranty.
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36 SEBU7992-02
Operation Section
Cold Weather Operation
i01903588
Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after you operate the engine.
Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more
information on priming the fuel system.
Fuel Heaters
Note: The OEM may equip the application with fuel
heaters. If this is the case, disconnect an electric type
of fuel heater in warm weather in order to prevent
overheating of the fuel. If the type of fuel heater is a
heat exchanger, the OEM should have included a
bypass for warm weather. Ensure that the bypass is
operational during warm weather in order to prevent
overheating of the fuel.
This document has been printed from SPI. Not for Resale
SEBU7992-02 37
Maintenance Section
Refill Capacities
reflect the approximate capacity of the crankcase Crankcase Oil Sump plus the capacity of factory installed oil
or sump plus standard oil filters. Auxiliary oil filter filters and other filters added to the lubrication system. Enter
the value for the capacity of the Total Lubrication System in
systems will require additional oil. Refer to the OEM this row.
specifications for the capacity of the auxiliary oil filter.
Refer to the Operation and Maintenance Manual,
Maintenance Section for more information on 403C-11 Engine
Lubricant Specifications. Table 11
403C-11 Engine
402C-05 Engine Refill Capacities
Table 9 Compartment or System Minimum Maximum
402C-05 Engine 3.4 L 4.9 L
Refill Capacities Crankcase Oil Sump(1)
(3.6 qt) (5.2 qt)
Compartment or System Minimum Maximum Total Lubrication System(2)
1.61 L 2.01 L (1) These values are the approximate capacities for the crankcase
Crankcase Oil Sump(1)
(1.7 qt) (2.1 qt) oil sump which includes the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
Total Lubrication System(2) to the OEM specifications for the capacity of the auxiliary oil
(1) filter.
These values are the approximate capacities for the crankcase (2) The Total Lubrication System includes the capacity for the
oil sump which includes the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer Crankcase Oil Sump plus the capacity of factory installed oil
to the OEM specifications for the capacity of the auxiliary oil filters and other filters added to the lubrication system. Enter
filter. the value for the capacity of the Total Lubrication System in
(2) The Total Lubrication System includes the capacity for the this row.
Crankcase Oil Sump plus the capacity of factory installed oil
filters and other filters added to the lubrication system. Enter 403C-15 and 403C-17 Engine
the value for the capacity of the Total Lubrication System in
this row.
Table 12
403C-15 and 403C-17 Engine
Refill Capacities
Compartment or System Minimum Maximum
4.5 L 6 L
Crankcase Oil Sump(1)
(4.8 qt) (6.3 qt)
Total Lubrication System(2)
(1) These values are the approximate capacities for the crankcase
oil sump which includes the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.
(2) The Total Lubrication System includes the capacity for the
Crankcase Oil Sump plus the capacity of factory installed oil
filters and other filters added to the lubrication system. Enter
the value for the capacity of the Total Lubrication System in
this row.
This document has been printed from SPI. Not for Resale
38 SEBU7992-02
Maintenance Section
Refill Capacities
Crankcase Oil Sump plus the capacity of factory installed oil the Engine plus the External System. Enter the value for the
filters and other filters added to the lubrication system. Enter capacity of the Total Cooling System in this row.
the value for the capacity of the Total Lubrication System in
this row.
403C-07 Engine
404C-22 and 404C-22T Engine Table 16
403C-07 Engine
Table 14
Refill Capacities
404C-22 and 404C-22T Engine
Refill Capacities Compartment or System Liters Quarts
This document has been printed from SPI. Not for Resale
SEBU7992-02 39
Maintenance Section
Refill Capacities
This document has been printed from SPI. Not for Resale
40 SEBU7992-02
Maintenance Section
Refill Capacities
This document has been printed from SPI. Not for Resale
SEBU7992-02 41
Maintenance Section
Refill Capacities
API CH-4 API CH-4 oils were developed in order to Total Base Number (TBN) and Fuel Sulfur
meet the requirements of the new high performance Levels for Diesel Engines
diesel engines. Also, the oil was designed to
meet the requirements of the low emissions diesel The Total Base Number (TBN) for an oil depends on
engines. API CH-4 oils are also acceptable for use the fuel sulfur level. For engines that use distillate
in older diesel engines and in diesel engines that fuel, the minimum TBN of the new oil must be
use high sulfur diesel fuel. API CH-4 oils may be 10 times the fuel sulfur level. The TBN is defined
used in Perkins engines that use API CG-4 and API by ASTM D2896. The minimum TBN of the oil
CF-4 oils. API CH-4 oils will generally exceed the is 5 regardless of fuel sulfur level. Illustration 26
performance of API CG-4 oils in the following criteria: demonstrates the TBN.
deposits on pistons, control of oil consumption, wear
of piston rings, valve train wear, viscosity control,
and corrosion.
This document has been printed from SPI. Not for Resale
42 SEBU7992-02
Maintenance Section
Refill Capacities
SAE 0W40 40 C (40 F) 40 C (104 F) These oils have lubricant viscosity grades of SAE
SAE 5W30 30 C (22 F) 30 C (86 F) 0W or SAE 5W.
SAE 5W40 30 C (22 F) 40 C (104 F) When an engine is started and operated in ambient
SAE 10W30 20 C (4 F) 40 C (104 F) temperatures below 30 C (22 F), use a synthetic
base stock multigrade oil with an 0W viscosity grade
SAE 15W40 10 C (14 F) 50 C (122 F) or with a 5W viscosity grade. Use an oil with a pour
point that is lower than 50 C (58 F).
Synthetic Base Stock Oils The number of acceptable lubricants is limited in
cold weather conditions. Perkins recommends the
Synthetic base oils are acceptable for use in following lubricants for use in cold weather conditions:
these engines if these oils meet the performance
requirements that are specified for the engine. First Choice Use oil with an EMA DHD-1
Recommended Guideline. Use a CH-4 oil that has
Synthetic base oils generally perform better than an API license. The oil should be either SAE 0W20,
conventional oils in the following two areas: SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
lubricant viscosity grade.
Synthetic base oils have improved flow at low
temperatures especially in arctic conditions. Second Choice Use an oil that has a CH-4
additive package. Although the oil has not been
Synthetic base oils have improved oxidation tested for the requirements of the API license, the oil
stability especially at high operating temperatures. must be either SAE 0W20, SAE 0W30, SAE 0W40,
SAE 5W30, or SAE 5W40.
Some synthetic base oils have performance
characteristics that enhance the service life of the
oil. Perkins does not recommend the automatic NOTICE
extending of the oil change intervals for any type of Shortened engine service life could result if second
oil. choice oils are used.
This document has been printed from SPI. Not for Resale
SEBU7992-02 43
Maintenance Section
Refill Capacities
Select the correct oil, or a commercial oil that meets Viscosity___________ 2,0 to 4.5 cSt at 40 C (104 F)
the EMA Recommended Guideline on Diesel
Engine Oil or the recommended API classification. Density________________________0.835 to 0.855 Kg/liter
This document has been printed from SPI. Not for Resale
44 SEBU7992-02
Maintenance Section
Refill Capacities
This is an indication of the mixture of different Group 3 (aviation kerosene fuels): Specification
hydrocarbons in the fuel. A high ratio of light weight
hydrocarbons can affect the characteristics of Performance of the engine may be reduced if these
combustion. fuels are used. To enable group 3 (aviation kerosene
fuels) to be used, 5% spindle oil must be added. The
Lubricity fuel injection pump will not be covered by a warranty,
even when additives are included.
This is the capability of the fuel to prevent pump wear.
JP5 MIL T5624 (Avcat FSII, NATO F44
Diesel engines have the ability to burn a wide variety
of fuels. These fuels are divided into four general JP8 T83133 (Avtur FSII, NATO F34
groups:
Jet A
Group 1 (preferred fuels)
Jet A1, NATO F35, XF63
Group 2 (permissible fuels)
Low temperature fuels
Group 3 (aviation kerosene fuels)
Special fuels for use in cold weather may be available
Other fuels for engine operation at temperatures below 0 C
(32 F). These fuels limit the formation of wax in the
Group 1 (preferred fuels): Specification fuel oil at low temperatures. If wax forms in the fuel
oil, this could stop the flow of fuel oil through the filter.
DERV to EN590
Note: These fuels that lack lubricity may cause the
Note: Only use Arctic fuels when the temperature is following problems:
below 0 C (32 F). Do not use Arctic fuels when the
ambient temperature is above 0 C (32 F). To ensure Low engine power
that the time period between cranking the engine and
first fire is kept to a minimum, only use fuel of the Difficult starting in hot conditions or in cold
correct viscosity and at the correct temperature. conditions
JIS K2204 (1992) Grades 1,2,3 and Special Grade Biofuel: Specification
3 This can only be used if the fuel has the correct
specification of lubricity. Biofuel: A 5% mix of RME to EN14214 in conventional
fuel is permitted.
Note: If low sulfur or low sulfur aromatic fuels are
used, then fuel additives can be used to increase NOTICE
lubricity. Water emulsion fuels: These fuels are not permitted
Group 2 (permissible fuels): Specification
Refer to the following fuel specifications for
These fuel specifications are considered acceptable North America.
for issues of warranty. However,these fuels may
reduce the life of the engine, the engines maximum The preferred fuels provide maximum engine service
power and the engines fuel efficiency. life and performance. The preferred fuels are distillate
fuels. These fuels are commonly called diesel fuel
ASTM D975 - 91 Class 1D or gas oil.
JP7, Mil T38219 The permissible fuels are crude oils or blended fuels.
Use of these fuels can result in higher maintenance
NATO F63 costs and in reduced engine service life.
NOTICE
These fuels should have a wear scar value of 650
micrometers maximum *HFRR to ISO 12156 - 1.*
This document has been printed from SPI. Not for Resale
SEBU7992-02 45
Maintenance Section
Refill Capacities
Diesel fuels that meet the specifications in Table (Table 25, contd)
25 will help to provide maximum engine service life Gum and Resins 10 mg per 100
and performance. In North America, diesel fuel that D381
(3) mL maximum
is identified as No. 2-D in ASTM D975 generally
meets the specifications. Table 25 is for diesel fuels 0.38 mm
that are distilled from crude oil. Diesel fuels from (0.015 inch)
Lubricity (4) D6079
maximum at
other sources could exhibit detrimental properties
25 C (77 F)
that are not defined or controlled by this specification.
(1) Perkins fuel systems and engine components can operate
Table 25 on high sulfur fuels. Fuel sulfur levels affect exhaust
emissions. High sulfur fuels also increase the potential
Perkins Specifications for Distillate Diesel Fuel for corrosion of internal components. Fuel sulfur levels
above 0.5 percent may significantly shorten the oil change
Specifications Requirements ASTM Test interval. For additional information, see this publication, Fluid
Recommendations/Engine Oil topic (Maintenance Section).
Aromatics 35% maximum D1319 (2) The values of the fuel viscosity are the values as the fuel
0.02% maximum is delivered to the fuel injection pumps. If a fuel with a low
Ash D482 viscosity is used, cooling of the fuel may be required to maintain
(weight)
a 1.4 cSt viscosity at the fuel injection pump. Fuels with a high
Carbon Residue 0.35% maximum viscosity might require fuel heaters in order to bring down the
D524 viscosity to a 20 cSt viscosity.
on 10% Bottoms (weight) (3) Follow the test conditions and procedures for gasoline (motor).
40 minimum (DI (4) The lubricity of a fuel is a concern with low sulfur fuel. To
Cetane Number engines) D613 determine the lubricity of the fuel, use either the ASTM D6078
Scuffing Load Wear Test (SBOCLE) or the ASTM D6079 High
The cloud Frequency Reciprocating Rig (HFRR) test. If the lubricity of a
fuel does not meet the minimum requirements, consult your
point must not
fuel supplier. Do not treat the fuel without consulting the fuel
exceed the - supplier. Some additives are not compatible. These additives
Cloud Point
lowest expected can cause problems in the fuel system.
ambient
temperature.
NOTICE
Copper Strip No. 3 maximum Operating with fuels that do not meet the Perkins rec-
D130
Corrosion ommendations can cause the following effects: Start-
10% at 282 C ing difficulty, poor combustion, deposits in the fuel in-
(540 F) jectors, reduced service life of the fuel system, de-
maximum posits in the combustion chamber, and reduced ser-
Distillation D86 vice life of the engine.
90% at 360 C
(680 F)
maximum
NOTICE
Flash Point legal limit D93 Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel
30 minimum
must NOT be used in Perkins diesel engines. Severe
API Gravity D287 component wear and component failures will result if
45 maximum HFO type fuels are used in engines that are configured
6 C (10 F)
to use distillate fuel.
minimum
Pour Point D97
below ambient In extreme cold ambient conditions, you may use the
temperature distillate fuels that are specified in Table 26. However,
0.2% maximum D3605 the fuel that is selected must meet the requirements
Sulfur (1) or that are specified in Table 25. These fuels are
D1552 intended to be used in operating temperatures that
are down to 54 C (65 F).
2.0 cSt minimum
Kinematic and 4.5 cSt
D445
Viscosity (2) maximum at
40 C (104 F)
Water and 0.1% maximum
D1796
Sediment
Water 0.1% maximum D1744
0.05% maximum
Sediment D473
(weight)
(continued)
This document has been printed from SPI. Not for Resale
46 SEBU7992-02
Maintenance Section
Refill Capacities
Table 26
Distillate Fuels (1) NOTICE
Never operate an engine without water temperature
Specification Grade regulators in the cooling system. Water temperature
MIL-T-5624R JP-5 regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
ASTM D1655 Jet-A-1 lems can develop without water temperature regula-
MIL-T-83133D JP-8 tors.
(1) The fuels that are listed in this Table may not meet the
requirements that are specified in the Perkins Specifications Many engine failures are related to the cooling
for Distillate Diesel Fuel Table. Consult the supplier for the system. The following problems are related to cooling
recommended additives in order to maintain the correct fuel system failures: Overheating, leakage of the water
lubricity.
pump, and plugged radiators or heat exchangers.
These fuels are lighter than the No. 2 grades of fuel.
These failures can be avoided with correct cooling
The cetane number of the fuels in Table 26 must be
system maintenance. Cooling system maintenance is
at least 40. If the viscosity is below 1.4 cSt at 38 C
as important as maintenance of the fuel system and
(100 F), use the fuel only in temperatures below
the lubrication system. Quality of the coolant is as
0 C (32 F). Do not use any fuels with a viscosity
important as the quality of the fuel and the lubricating
of less than 1.2 cSt at 38 C (100 F). Fuel cooling
oil.
may be required in order to maintain the minimum
viscosity of 1.4 cSt at the fuel injection pump.
Coolant is normally composed of three elements:
Water, additives, and glycol.
There are many other diesel fuel specifications that
are published by governments and by technological
societies. Usually, those specifications do not Water
review all the requirements that are addressed
in this specification. To ensure optimum engine Water is used in the cooling system in order to
performance, a complete fuel analysis should be transfer heat.
obtained before engine operation. The fuel analysis
should include all of the properties that are listed in Distilled water or deionized water is
Table 25. recommended for use in engine cooling systems.
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SEBU7992-02 47
Maintenance Section
Refill Capacities
Additives Table 28
Ethylene Glycol
Additives help to protect the metal surfaces of
the cooling system. A lack of coolant additives or Freeze Boil
Concentration
insufficient amounts of additives enable the following Protection Protection
conditions to occur: 50 Percent 36 C (33 F) 106 C (223 F)
Glycol in the coolant helps to provide protection Acceptable A commercial heavy-duty coolant that
against the following conditions: meets ASTM D4985 specifications
Boiling NOTICE
Do not use a commercial coolant/antifreeze that on-
Freezing ly meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light automotive appli-
Cavitation of the water pump cations.
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48 SEBU7992-02
Maintenance Section
Refill Capacities
In stationary engine applications and marine engine ELC is available in a 1:1 premixed cooling solution
applications that do not require anti-boil protection with distilled water. The Premixed ELC provides
or freeze protection, a mixture of SCA and water freeze protection to 36 C (33 F). The Premixed
is acceptable. Perkins recommends a six percent ELC is recommended for the initial fill of the cooling
to eight percent concentration of SCA in those system. The Premixed ELC is also recommended for
cooling systems. Distilled water or deionized water topping off the cooling system.
is preferred. Water which has the recommended
properties may be used. ELC Concentrate is also available. ELC Concentrate
can be used to lower the freezing point to 51 C
Engines that are operating in an ambient temperature (60 F) for arctic conditions.
above 43 C (109.4 F) must use SCA and water.
Engines that operate in an ambient temperature Containers of several sizes are available. Consult
above 43 C (109.4 F) and below 0 C (32 F) due your Perkins dealer or your Perkins distributor for the
to seasonal variations consult your Perkins dealer part numbers.
or your Perkins distributor for the correct level of
protection.
ELC Cooling System Maintenance
Table 30
Coolant Service Life
Correct additions to the Extended Life
Coolant
Coolant Type Service Life
12,000 Service Hours NOTICE
Perkins ELC
or Six Years Use only Perkins products for pre-mixed or concen-
Commercial Heavy-Duty
trated coolants.
3000 Service Hours or
Coolant that meets
Two Years Use only Perkins Extender with Extended Life
ASTM D4985
Coolant.
Perkins POWERPART 3000 Service Hours or
SCA Two Years Mixing Extended Life Coolant with other products re-
Commercial SCA and 3000 Service Hours or duces the Extended Life Coolant service life. Failure to
Water Two Years follow the recommendations can reduce cooling sys-
tem components life unless appropriate corrective ac-
tion is performed.
Extended Life Coolant (ELC)
Perkins provides Extended Life Coolant (ELC) for In order to maintain the correct balance between
use in the following applications: the antifreeze and the additives, you must maintain
the recommended concentration of Extended Life
Heavy-duty spark ignited gas engines Coolant (ELC). Lowering the proportion of antifreeze
lowers the proportion of additive. This will lower the
Heavy-duty diesel engines ability of the coolant to protect the system from pitting,
from cavitation, from erosion, and from deposits.
Automotive applications
NOTICE
The anti-corrosion package for ELC is different from Do not use a conventional coolant to top-off a cooling
the anti-corrosion package for other coolants. ELC system that is filled with Extended Life Coolant (ELC).
is an ethylene glycol base coolant. However, ELC
contains organic corrosion inhibitors and antifoam Do not use standard supplemental coolant additive
agents with low amounts of nitrite. Perkins ELC (SCA). Only use ELC Extender in cooling systems that
has been formulated with the correct amount of are filled with ELC.
these additives in order to provide superior corrosion
protection for all metals in engine cooling systems.
Perkins ELC Extender
ELC extends the service life of the coolant to 12000
service hours or six years. ELC does not require ELC Extender is added to the cooling system halfway
a frequent addition of a Supplemental Coolant through the ELC service life. Treat the cooling system
Additive (SCA). An Extender is the only additional with ELC Extender at 6000 hours or three years. Use
maintenance that is needed at 6000 service hours or Table 31 in order to determine the correct amount of
one half of the ELC service life. ELC Extender that is required.
This document has been printed from SPI. Not for Resale
SEBU7992-02 49
Maintenance Section
Refill Capacities
Table 32
4. Use Perkins cleaner to clean the system. Follow
the instruction on the label.
Example Of The Equation For Adding ELC
Extender To ELC 5. Drain the cleaner into a suitable container. Flush
Total Volume Multiplication Amount of ELC the cooling system with clean water.
of the Cooling Factor Extender that is
System (V) Required (X) 6. Fill the cooling system with clean water and
operate the engine until the engine is warmed to
0.18 L
49 to 66C (120 to 150F).
9 L (2.4 US gal) 0.02 (0.05 US gal)
or (6 fl oz)
NOTICE
Incorrect or incomplete flushing of the cooling system
NOTICE can result in damage to copper and other metal com-
When using Perkins ELC, do not use standard SCAs ponents.
or SCA filters.
To avoid damage to the cooling system, make sure to
ELC Cooling System Cleaning completely flush the cooling system with clear water.
Continue to flush the system until all the signs of the
Note: If the cooling system is already using ELC, cleaning agent are gone.
cleaning agents are not required to be used at
the specified coolant change interval. Cleaning 7. Drain the cooling system into a suitable container
agents are only required if the system has been and flush the cooling system with clean water.
contaminated by the addition of some other type of
coolant or by cooling system damage. Note: The cooling system cleaner must be thoroughly
flushed from the cooling system. Cooling system
Clean water is the only cleaning agent that is required cleaner that is left in the system will contaminate the
when ELC is drained from the cooling system. coolant. The cleaner may also corrode the cooling
system.
After the cooling system is drained and after the
cooling system is refilled, operate the engine while 8. Repeat Steps 6 and 7 until the system is
the cooling system filler cap is removed. Operate completely clean.
the engine until the coolant level reaches the normal
operating temperature and until the coolant level 9. Fill the cooling system with the Perkins Premixed
stabilizes. As needed, add the coolant mixture in ELC.
order to fill the system to the specified level.
This document has been printed from SPI. Not for Resale
50 SEBU7992-02
Maintenance Section
Refill Capacities
ELC Cooling System Contamination Additions of SCA are based on the results of the test.
An SCA that is liquid may be needed at 500 hour
intervals.
NOTICE
Mixing ELC with other products reduces the effective-
Refer to Table 33 for part numbers and for quantities
ness of the ELC and shortens the ELC service life.
of SCA.
Use only Perkins Products for premixed or concen-
trate coolants. Use only Perkins ELC extender with Table 33
Perkins ELC. Failure to follow these recommenda-
tions can result in shortened cooling system compo- Perkins Liquid SCA
nent life. Part Number Quantity
21825735 .
ELC cooling systems can withstand contamination to
a maximum of ten percent of conventional heavy-duty
coolant or SCA. If the contamination exceeds ten Adding the SCA to Heavy-Duty Coolant
percent of the total system capacity, perform ONE of at the Initial Fill
the following procedures:
Commercial heavy-duty coolant that meets ASTM
Drain the cooling system into a suitable container. D4985 specifications MAY require an addition of
Dispose of the coolant according to local SCA at the initial fill. Read the label or the instructions
regulations. Flush the system with clean water. Fill that are provided by the OEM of the product.
the system with the Perkins ELC.
Use the equation that is in Table 34 to determine the
Drain a portion of the cooling system into a suitable amount of Perkins SCA that is required when the
container according to local regulations. Then, fill cooling system is initially filled.
the cooling system with premixed ELC. This should
lower the contamination to less than 10 percent. Table 34
Equation For Adding The SCA To The Heavy-Duty
Maintain the system as a conventional Heavy-Duty Coolant At The Initial Fill
Coolant. Treat the system with an SCA. Change
the coolant at the interval that is recommended for V 0.045 = X
the conventional Heavy-Duty Coolant.
V is the total volume of the cooling system.
This document has been printed from SPI. Not for Resale
SEBU7992-02 51
Maintenance Section
Refill Capacities
Table 36
Equation For Adding The SCA To The Heavy-Duty
Coolant For Maintenance
V 0.014 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
Table 37
Example Of The Equation For Adding The SCA To
The Heavy-Duty Coolant For Maintenance
Total Volume Multiplication Amount of SCA
of the Cooling Factor that is Required
System (V) (X)
15 L (4 US gal) 0.014 0.2 L (7 oz)
This document has been printed from SPI. Not for Resale
52 SEBU7992-02
Maintenance Section
Maintenance Interval Schedule
Ensure that the Safety Information, Warnings, Every 2000 Service Hours
and Instructions are read and understood
before operation or maintenance procedures are Alternator - Inspect ............................................... 53
performed. Engine Crankcase Breather - Replace ................. 62
Engine Mounts - Inspect ....................................... 63
Note: The frequency that the engine oil is changed Starting Motor - Inspect ........................................ 74
will be affected if the load factor for the engine
is greater than 40 percent. Consult your Perkins Every 3000 Service Hours
distributor if assistance is required to calculate the
load factor for your engine. Fuel Injector - Test/Change ................................... 66
Water Pump - Inspect ........................................... 76
Before each consecutive interval is performed, all
of the maintenance requirements from the previous Every 3000 Service Hours or 2 Years
interval must also be performed.
Cooling System Coolant (Commercial Heavy-Duty) -
Change ............................................................... 56
When Required
Battery - Replace .................................................. 54 Every 6000 Service Hours or 3 Years
Battery or Battery Cable - Disconnect .................. 55
Cooling System Coolant Extender (ELC) - Add .... 59
Engine - Clean ...................................................... 61
Engine Air Cleaner Element (Single Element) -
Inspect/Replace .................................................. 61
Every 12 000 Service Hours or 6 Years
Fuel System - Prime ............................................. 67 Cooling System Coolant (ELC) - Change ............. 57
Severe Service Application - Check ..................... 73
Daily
Cooling System Coolant Level - Check ................ 59
Driven Equipment - Check .................................... 61
Engine Air Cleaner Service Indicator - Inspect ..... 62
Engine Oil Level - Check ...................................... 63
Fuel System Primary Filter/Water Separator -
Drain ................................................................... 71
Walk-Around Inspection ........................................ 75
This document has been printed from SPI. Not for Resale
SEBU7992-02 53
Maintenance Section
Alternator - Inspect
i02322311
Alternator - Inspect
Inspection
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
This document has been printed from SPI. Not for Resale
54 SEBU7992-02
Maintenance Section
Alternator and Fan Belts - Replace
i02166560
Batteries give off combustible gases which can
Alternator and Fan Belts - explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
Replace jury or death.
g01091158
2. Turn off any battery chargers. Disconnect any
Illustration 29 battery chargers.
Typical example
(1) Adjusting bolt 3. The NEGATIVE - cable connects the NEGATIVE
(2) Mounting bolts - battery terminal to the NEGATIVE - terminal
on the starting motor. Disconnect the cable from
For applications that require multiple drive belts, the NEGATIVE - battery terminal.
replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to 4. The POSITIVE + cable connects the POSITIVE
carry more load because the older belt is stretched. + battery terminal to the POSITIVE + terminal
The additional load on the new belt could cause the on the starting motor. Disconnect the cable from
new belt to break. the POSITIVE + battery terminal.
Note: When new belts are installed, check the belt Note: Always recycle a battery. Never discard a
tension again after 20 hours of engine operation. battery. Dispose of used batteries to an appropriate
recycling facility.
Refer to the Disassembly and Assembly Manual for
the installation procedure and the removal procedure 5. Remove the used battery.
for the belt.
6. Install the new battery.
This document has been printed from SPI. Not for Resale
SEBU7992-02 55
Maintenance Section
Battery Electrolyte Level - Check
Clean the battery case with one of the following 6. Tape the cable connections in order to help
cleaning solutions: prevent accidental starting.
Use a solution of 0.1 kg (0.2 lb) baking soda 7. Proceed with necessary system repairs.
and 1 L (1 qt) of clean water.
8. In order to connect the battery, connect the
Use a solution of ammonium hydroxide. positive connection before the negative connector.
This document has been printed from SPI. Not for Resale
56 SEBU7992-02
Maintenance Section
Cooling System Coolant (Commercial Heavy-Duty) - Change
Change
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
NOTICE
Keep all parts clean from contaminants.
This document has been printed from SPI. Not for Resale
SEBU7992-02 57
Maintenance Section
Cooling System Coolant (ELC) - Change
3. Fill the cooling system with clean water. Install the 6. Start the engine. Inspect the cooling system for
cooling system filler cap. leaks and for correct operating temperature.
Cooling system air locks may result in engine damage. Contaminants may cause rapid wear and shortened
component life.
2. Fill the cooling system with Commercial
Heavy-Duty Coolant. Add Supplemental Coolant Clean the cooling system and flush the cooling
Additive to the coolant. For the correct amount, system before the recommended maintenance
refer to the Operation and Maintenance Manual, interval if the following conditions exist:
Fluid Recommendations topic (Maintenance
Section) for more information on cooling system The engine overheats frequently.
specifications. Do not install the cooling system
filler cap. Foaming is observed.
3. Start and run the engine at low idle. Increase the The oil has entered the cooling system and the
engine rpm to high idle. Run the engine at high coolant is contaminated.
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine. The fuel has entered the cooling system and the
coolant is contaminated.
4. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the Note: When the cooling system is cleaned, only
pipe for filling. Maintain the coolant level in the clean water is needed when the ELC is drained and
expansion bottle (if equipped) at the correct level. replaced.
5. Clean the cooling system filler cap. Inspect the Note: Inspect the water pump and the water
gasket that is on the cooling system filler cap. If temperature regulator after the cooling system has
the gasket that is on the cooling system filler cap been drained. This is a good opportunity to replace
is damaged, discard the old cooling system filler the water pump, the water temperature regulator and
cap and install a new cooling system filler cap. If the hoses, if necessary.
the gasket that is on the cooling system filler cap
is not damaged, use a suitable pressurizing pump
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap.
This document has been printed from SPI. Not for Resale
58 SEBU7992-02
Maintenance Section
Cooling System Coolant (ELC) - Change
Drain Flush
1. Flush the cooling system with clean water in order
to remove any debris.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, 2. Close the drain cock or install the drain plug in the
stop the engine and wait until the cooling system engine. Close the drain cock or install the drain
components are cool. Loosen the cooling system plug on the radiator.
pressure cap slowly in order to relieve the pres-
sure. NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in Cooling system air locks may result in engine damage.
order to relieve any pressure. Remove the cooling
system filler cap.
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
Fill
1. Close the drain cock or install the drain plug on the
engine. Close the drain cock or install the drain
plug on the radiator.
g01087295
Illustration 31 NOTICE
Typical example Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
2. Open the drain cock or remove the drain plug (1)
on the engine. Open the drain cock or remove the Cooling system air locks may result in engine damage.
drain plug on the radiator.
Allow the coolant to drain. 2. Fill the cooling system with Extended Life
Coolant (ELC). Refer to the Operation and
Maintenance Manual, Fluid Recommendations
NOTICE
topic (Maintenance Section) for more information
Dispose of used engine coolant or recycle. Various
on cooling system specifications. Do not install the
methods have been proposed to reclaim used coolant
cooling system filler cap.
for reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Perkins to
3. Start and run the engine at low idle. Increase the
reclaim the coolant.
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
For information regarding the disposal and the the cavities of the engine block. Stop the engine.
recycling of used coolant, consult your Perkins dealer
or your Perkins distributor. 4. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level in the
expansion bottle (if equipped) at the correct level.
This document has been printed from SPI. Not for Resale
SEBU7992-02 59
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Cooling System Coolant 1. Observe the coolant level in the coolant recovery
tank. Maintain the coolant level to COLD FULL
Extender (ELC) - Add mark on the coolant recovery tank.
1. Loosen the cooling system filler cap slowly in 2. Loosen filler cap slowly in order to relieve any
order to relieve pressure. Remove the cooling pressure. Remove the filler cap.
system filler cap.
3. Pour the correct coolant mixture into the tank.
2. It may be necessary to drain enough coolant from Refer to the Operation and Maintenance Manual,
the cooling system in order to add the Extender. Refill Capacities and Recommendations for
information on the correct mixture and type of
3. Add Extender according to the requirements for coolant. Refer to the Operation and Maintenance
your engines cooling system capacity. Refer to Manual, Refill Capacities and Recommendations
this Operation and Maintenance Manual, Refill for the cooling system capacity. Do not fill the
Capacities in the Maintenance Section for the coolant recovery tank above COLD FULL mark.
capacity of the cooling system for your engine.
Refer to this Operation and Maintenance Manual,
Fluid Recommendations information for the
Perkins ELC Extender.
g00103639
Illustration 32
This document has been printed from SPI. Not for Resale
60 SEBU7992-02
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
NOTICE
Do not exceed the recommended amount of sup-
plemental coolant additive concentration. Excessive
Pressurized System: Hot coolant can cause seri- supplemental coolant additive concentration can form
ous burns. To open the cooling system filler cap, deposits on the higher temperature surfaces of the
stop the engine and wait until the cooling system cooling system, reducing the engines heat transfer
components are cool. Loosen the cooling system characteristics. Reduced heat transfer could cause
pressure cap slowly in order to relieve the pres- cracking of the cylinder head and other high temper-
sure. ature components. Excessive supplemental coolant
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water
1. Remove the cooling system filler cap slowly in
pump seal wear. Never use both liquid supplemental
order to relieve pressure.
coolant additive and the spin-on element (if equipped)
at the same time. The use of those additives together
2. Maintain the coolant level within 13 mm (0.5 inch)
could result in supplemental coolant additive concen-
of the bottom of the filler pipe. If the engine is
tration exceeding the recommended maximum.
equipped with a sight glass, maintain the coolant
level to the correct level in the sight glass.
This document has been printed from SPI. Not for Resale
SEBU7992-02 61
Maintenance Section
Driven Equipment - Check
3. Add the correct amount of SCA. Refer to the Moisture can create paths of electrical conductiv-
Operation and Maintenance Manual, Refill ity.
Capacities and Recommendations for more
information on SCA requirements. Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls DO
4. Clean the cooling system filler cap and inspect the NOT OPERATE.
gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket
is not damaged, use a suitable pressurizing pump NOTICE
in order to pressure test the filler cap. The correct Accumulated grease and oil on an engine is a fire haz-
pressure is stamped on the face of the filler cap. If ard. Keep the engine clean. Remove debris and fluid
the filler cap does not retain the correct pressure, spills whenever a significant quantity accumulates on
install a new filler cap. the engine.
i02152042
This document has been printed from SPI. Not for Resale
62 SEBU7992-02
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Some engines may be equipped with a different The service indicator may need to be replaced
service indicator. frequently in environments that are severely dusty.
The service indicator may be mounted on the air Contaminants may cause rapid wear and shortened
cleaner element or in a remote location. component life.
g00103777
Illustration 34
Typical service indicator
This document has been printed from SPI. Not for Resale
SEBU7992-02 63
Maintenance Section
Engine Mounts - Inspect
i02323089
1. Loosen the screws (1) and remove the breather Engine Oil Level - Check
cover (2) from the valve mechanism cover.
3. For turbocharged engines, remove the spacer (5) Hot oil and hot components can cause personal
and the joint (6). injury. Do not allow hot oil or hot components to
contact the skin.
4. Clean the vent hole (8) and the cavity (7) in the
valve mechanism cover.
NOTICE
Make sure that the components of the breather as-
sembly are installed correctly. Engine damage may
occur if the breather assembly is not working correctly.
This document has been printed from SPI. Not for Resale
64 SEBU7992-02
Maintenance Section
Engine Oil and Filter - Change
1. Maintain the oil level between ADD mark (Y) and Drain the Engine Oil
FULL mark (X) on oil level gauge (1). Do not fill
the crankcase above FULL mark (X). After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
NOTICE
Operating your engine when the oil level is above the If the engine is equipped with a drain valve, turn the
FULL mark could cause your crankshaft to dip into drain valve knob counterclockwise in order to drain
the oil. The air bubbles created from the crankshaft the oil. After the oil has drained, turn the drain valve
dipping into the oil reduces the oils lubricating char- knob clockwise in order to close the drain valve.
acteristics and could result in the loss of power.
If the engine is not equipped with a drain valve,
2. Remove the oil filler cap and add oil, if necessary. remove the oil drain plug in order to allow the oil to
Clean the oil filler cap. Install the oil filler cap. drain. After the oil has drained, the oil drain plug
should be cleaned and installed.
i02610655
Replace the Oil Filter
Engine Oil and Filter - Change
NOTICE
Perkins oil filters are built to Perkins specifications.
Use of an oil filter not recommended by Perkins could
result in severe engine damage to the engine bear-
ings, crankshaft, etc., as a result of the larger waste
Hot oil and hot components can cause personal particles from unfiltered oil entering the engine lubri-
injury. Do not allow hot oil or hot components to cating system. Only use oil filters recommended by
contact the skin. Perkins.
This document has been printed from SPI. Not for Resale
SEBU7992-02 65
Maintenance Section
Engine Valve Lash - Inspect/Adjust
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
g01334593
Illustration 37
(1) Oil cooler
(2) Adapter g00986928
(3) Oil filter Illustration 38
Typical example
Note: The oil cooler (1) and the adapter (2) are
installed on engines that have a turbocharger. 4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the MIN
3. Clean the sealing surface of the cylinder block or and MAX marks on the oil level gauge.
the oil cooler (1).
4. Apply clean engine oil to the new oil filter seal (3). i02171102
This document has been printed from SPI. Not for Resale
66 SEBU7992-02
Maintenance Section
Fuel Injector - Test/Change
Fuel leaked or spilled onto hot surfaces or electri- For further information on the testing of fuel injectors,
cal components can cause a fire. refer to the Testing and Adjusting manual.
This document has been printed from SPI. Not for Resale
SEBU7992-02 67
Maintenance Section
Fuel System - Prime
i02153676
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
This document has been printed from SPI. Not for Resale
68 SEBU7992-02
Maintenance Section
Fuel System Filter - Replace
i02154450
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
g01122127
Illustration 42
Connector that is installed on 4 cylinder engines
(6) Connector bolt
Note: For illustration 41, the fuel return hose (5) may
need to be removed at the fuel injection pump.
This document has been printed from SPI. Not for Resale
SEBU7992-02 69
Maintenance Section
Fuel System Filter - Replace
g01122129
Illustration 43
g00917937
Illustration 44
This document has been printed from SPI. Not for Resale
70 SEBU7992-02
Maintenance Section
Fuel System Filter - Replace
g01122130
Illustration 45
g01122131
Illustration 46
This document has been printed from SPI. Not for Resale
SEBU7992-02 71
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
i02177959 i02335436
NOTICE
Care must be taken to ensure that fluids are contained
Fuel leaked or spilled onto hot surfaces or elec- during performance of inspection, maintenance, test-
trical components can cause a fire. To help pre- ing, adjusting, and repair of the product. Be prepared
vent possible injury, turn the start switch off when to collect the fluid with suitable containers before
changing fuel filters or water separator elements. opening any compartment or disassembling any com-
Clean up fuel spills immediately. ponent containing fluids.
Illustration 47
g00741109 Open the drain valve on the bottom of the fuel tank
(1) Cap
in order to drain the water and the sediment. Close
(2) Locking ring the drain valve.
(3) Element
(4) Water separator bowl Check the fuel daily. Allow five minutes after the
(5) Drain fuel tank has been filled before draining water and
sediment from the fuel tank.
1. Open drain (5). Catch the draining water in a
suitable container. Dispose of the drained water Fill the fuel tank after operating the engine in
correctly. order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
2. Close drain (5). fuel expands as the fuel gets warm. The tank may
overflow.
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.
This document has been printed from SPI. Not for Resale
72 SEBU7992-02
Maintenance Section
Hoses and Clamps - Inspect/Replace
Some fuel tanks use supply pipes that allow water End fittings that are damaged or leaking
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that Outer covering that is chafed or cut
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular Exposed wire that is used for reinforcement
maintenance of the fuel system filter is important.
Outer covering that is ballooning locally
Fuel Storage Tanks
Flexible part of the hose that is kinked or crushed
Drain the water and the sediment from the fuel
storage tank at the following intervals: Armoring that is embedded in the outer covering
A constant torque hose clamp can be used in place
Weekly of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
Service intervals clamp.
Refill of the tank Due to extreme temperature changes, the hose will
harden. Hardening of the hoses will cause hose
This will help prevent water or sediment from being
clamps to loosen. This can result in leaks. A constant
pumped from the storage tank into the engine fuel
torque hose clamp will help to prevent loose hose
tank.
clamps.
If a bulk storage tank has been refilled or moved
Each installation application can be different. The
recently, allow adequate time for the sediment to
differences depend on the following factors:
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 Type of hose
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. Type of fitting material
Anticipated expansion and contraction of the hose
i02813964
Anticipated expansion and contraction of the
Hoses and Clamps - fittings
Inspect/Replace
Replace the Hoses and the Clamps
Refer to the OEM information for further information
Inspect all hoses for leaks that are caused by the on removing and replacing fuel hoses (if equipped).
following conditions:
The coolant system and the hoses for the coolant
Cracking system are not usually supplied by Perkins. The
following text describes a typical method of replacing
Softness coolant hoses. Refer to the OEM information for
further information on the coolant system and the
Loose clamps hoses for the coolant system.
This document has been printed from SPI. Not for Resale
SEBU7992-02 73
Maintenance Section
Radiator - Clean
5. Disconnect the old hose. Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
6. Replace the old hose with a new hose. to the fans air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the radiator fins. Slowly
7. Install the hose clamps with a torque wrench. move the air nozzle in a direction that is parallel with
the radiator tube assembly. This will remove debris
Note: For the correct coolant, see this Operation and that is between the tubes.
Maintenance Manual, Fluid Recommendations.
Pressurized water may also be used for cleaning.
8. Refill the cooling system. Refer to the OEM The maximum water pressure for cleaning purposes
information for further information on refilling the must be less than 275 kPa (40 psi). Use pressurized
cooling system. water in order to soften mud. Clean the core from
both sides.
9. Clean the cooling system filler cap. Inspect the
cooling system filler caps seals. Replace the Use a degreaser and steam for removal of oil and
cooling system filler cap if the seals are damaged. grease. Clean both sides of the core. Wash the core
Install the cooling system filler cap. with detergent and hot water. Thoroughly rinse the
core with clean water.
10. Start the engine. Inspect the cooling system for
leaks. If the radiator is blocked internally, refer to the OEM
Manual for information regarding flushing the cooling
system.
i02335774
Radiator - Clean After cleaning the radiator, start the engine. Allow
the engine to operate at low idle speed for three to
five minutes. Accelerate the engine to high idle. This
will help in the removal of debris and the drying of
The radiator is not usually supplied by Perkins. The the core. Slowly reduce the engine speed to low idle
following text describes a typical cleaning procedure and then stop the engine. Use a light bulb behind
for the radiator. Refer to the OEM information for the core in order to inspect the core for cleanliness.
further information on cleaning the radiator. Repeat the cleaning, if necessary.
Note: Adjust the frequency of cleaning according to Inspect the fins for damage. Bent fins may be opened
the effects of the operating environment. with a comb. Inspect these items for good condition:
Welds, mounting brackets, air lines, connections,
Inspect the radiator for these items: Damaged fins, clamps, and seals. Make repairs, if necessary.
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary. i02335775
This document has been printed from SPI. Not for Resale
74 SEBU7992-02
Maintenance Section
Starting Motor - Inspect
Performance such as power range, speed range, Altitude Problems can arise when the engine is
and fuel consumption operated at altitudes that are higher than the intended
settings for that application. Necessary adjustments
Fuel quality should be made.
Quality of the air The engine may be exposed A regular visual inspection of the turbocharger is
to extended operation in an environment that is recommended. Any fumes from the crankcase are
dirty or dusty, unless the equipment is cleaned filtered through the air inlet system. Therefore,
regularly. Mud, dirt and dust can encase components. by-products from oil and from combustion can collect
Maintenance can be very difficult. The buildup can in the turbocharger compressor housing. Over time,
contain corrosive chemicals. this buildup can contribute to loss of engine power,
increased black smoke and overall loss of engine
Buildup Compounds, elements, corrosive efficiency.
chemicals and salt can damage some components.
This document has been printed from SPI. Not for Resale
SEBU7992-02 75
Maintenance Section
Walk-Around Inspection
If the turbocharger fails during engine operation, 2. Check for the presence of oil. If oil is leaking from
damage to the turbocharger compressor wheel the back side of the compressor wheel, there is a
and/or to the engine may occur. Damage to the possibility of a failed turbocharger oil seal.
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder The presence of oil may be the result of extended
head. engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
NOTICE for the intake air (clogged air filters), which causes
Turbocharger bearing failures can cause large quanti- the turbocharger to slobber.
ties of oil to enter the air intake and exhaust systems.
Loss of engine lubricant can result in serious engine 3. Inspect the bore of the housing of the turbine
damage. outlet for corrosion.
Minor leakage of oil into a turbocharger under extend- 4. Fasten the air intake pipe and the exhaust outlet
ed low idle operation should not cause problems as pipe to the turbocharger housing.
long as a turbocharger bearing failure has not oc-
cured. i02177973
NOTICE NOTICE
The compressor housing for the turbocharger must For any type of leak (coolant, lube, or fuel) clean up the
not be removed from the turbocharger for cleaning. fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
The actuator linkage is connected to the compressor more often than recommended until the leak is found
housing. If the actuator linkage is moved or disturbed or fixed, or until the suspicion of a leak is proved to be
the engine may not comply with emmissions legisla- unwarranted.
tion.
NOTICE
1. Remove the pipe from the turbocharger exhaust
Accumulated grease and/or oil on an engine is a fire
outlet and remove the air intake pipe to the
hazard. Remove the accumulated grease and oil. Re-
turbocharger. Visually inspect the piping for the
fer to this Operation and Maintenance Manual, En-
presence of oil. Clean the interior of the pipes
gine - Clean for more information.
in order to prevent dirt from entering during
reassembly.
This document has been printed from SPI. Not for Resale
76 SEBU7992-02
Maintenance Section
Water Pump - Inspect
This document has been printed from SPI. Not for Resale
SEBU7992-02 77
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i01903596
Emissions Warranty
Information
This document has been printed from SPI. Not for Resale
78 SEBU7992-02
Index Section
Index
A E
This document has been printed from SPI. Not for Resale
SEBU7992-02 79
Index Section
Table of Contents..................................................... 3
H Turbocharger - Inspect (If Equipped)..................... 74
Inspecting........................................................... 75
Hoses and Clamps - Inspect/Replace ................... 72 Removal and Installation.................................... 75
Replace the Hoses and the Clamps .................. 72
W
I
Walk-Around Inspection ........................................ 75
Important Safety Information ................................... 2 Inspect the Engine for Leaks and for Loose
Connections ..................................................... 75
Warranty Information ............................................. 77
L Warranty Section ................................................... 77
Water Pump - Inspect............................................ 76
Lifting and Storage ................................................ 23
Operation Section.................................................. 23
This document has been printed from SPI. Not for Resale
80 SEBU7992-02
Index Section
This document has been printed from SPI. Not for Resale
Product and Dealer Information
Note: For product identification plate locations, see the section Product Identification Information in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
This document has been printed from SPI. Not for Resale
2007 Perkins Engines Company Limited
This document has been printed from SPI. Not forPrinted
All Rights Reserved
Resale
in U. K.