Operation and Maintenance Manual Perkins

117765
DPerkins®
Operation and Maintenance
Manual
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1100A/BIC Series
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LIM of "'~a. ~r" ~ Eli ot,
PIN SEBU7833-01
OPERATION & MAINTENANCE ;
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11 11111 11 111 1111111 111111111111111111111111
Models DC, DO, OF, DG, OJ, OK,

RE, RG, RJ, RR and RS
SEBU 7833-01
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CALIFORNIA
Proposition 65 Warning
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Diesel engine exhaust and some of its constituents are known to
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the State of California to cause cancer, birth defects, and other

reproductive harm.
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SEBU7833-0 1
~Perkinso< December 2004
Operation and
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Maintenance
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Manual
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1103 and 1104 Engines
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DC (Engine)
DO (Engine)
OJ (Engine)
OK (Engine)
RE (Engine)
RG (Engine)
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RJ (Engine)
RR (Engine)
RS (Engine)
OF (Engine)
OG (Engine)
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101658146
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.
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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
"DAN GER", "WARN IN G" or "CAUTION". The Safety Alert "WARNING" label is shown below.
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A WARNING
The meaning of this safety alert symbol is as follows:
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Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
this publication .
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Operations that may cause product damage are identified by "NOTICE" labels on the product and in
Perkins cannot anticipate every possible circumstance that might involve a potential hazard.
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The warnings in this publication and on the product are, therefore, not all inclusive. If a tool ,
procedure, work method or operating technique that is not specifically recommended by Perkins
is used, you must satisfy yourself that it is safe for you and for others . You should also ensure that
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the product will not be damaged or be made unsafe by the operation , lubrication, maintenance or
repair procedures that you choose.
The information , specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments , illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
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start any job. Perkins dealers have the most current information available.
A WARNING
When replacement parts are required for this
product Perkins recommends using Perkins
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replacement parts or parts with equivalent

specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

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ture failures, product damage, personal injury or

death.
SEBU7833-01 3
Table of Contents
Table of Contents
Foreword ................................•............................... 4
Safety Section
Safety Messages ................. ................................ .. 5
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General Hazard Information . .. ............................... 5
Burn Prevention .. ............................. ....................... 7
Fire Prevention and Explosion Prevention .............. 7
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Crushing Prevention and Cutting Prevention .......... 9
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Mounting and Dismounting .................................... 9
Before Starting Engine .... .... .......... ..................... 9
Engine Starting .................................................... 10
Engine Stopping ............... .....•... ........................... 10

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Electrica l System ...... .............. ......... ........... .... ...... 10
Product Information Section

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Model Views .. ...... ........... .... ... .... .......... ... .... ...... .... 12
Product Identification Information ........................ 18
Operation Section
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Lifting and Storage ... ... ........................ ......... ......... 21
Gauges and Indicators ....................••............•....... 24
Engine Starting .............................. ....................... 25

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Engine Operation ................................. ............ ..... 28
Engine Stopping .............. .......... ........................... 29
Cold Weather Operation .............. ........................ 30

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Maintenance Section
Refill Capacities ................................................... 34
Maintenance Interval Schedule ............... ............ 48
Warranty Section
Warranty Information ............................... .•.. ......... 76
Index Section
Index ..... ......................... .... ... ............................ 77
4 SEBU7833-01
Foreword
Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe ,
This manual contains safety, operation instructions, dusty, wet or freezing cold operating conditions,
lubrication and maintenance information. This more frequent lubrication and maintenance than is
manual should be stored in or near the engine area specified in the Maintenance Interval Schedule may
in a literature holder or literature storage area. Read , be necessary.
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study and keep it with the literature and engine
information. The maintenance schedule items are organized for
a preventive maintenance management program. If
English is the primary language for all Perkins the preventive maintenance program is followed , a
publications. The English used facilitates translation periodic tune-up is not required . The implementation
and consistency.
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of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures .
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from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design Maintenance Intervals
may have caused changes to your engine which are
not included in this manual. Whenever a question Perform maintenance on items at multiples of
arises regarding your engine, or this manual, please
consult with your Perkins dealer or your Perkins
distributor for the latest available information. E the original requirement. We recommend that the
maintenance schedules be reproduced and displayed
near the engine as a convenient reminder. We also
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recommend that a maintenance record be maintained
as part of the engine's permanent record .
Safety
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Your authorized Perkins dealer or your Perkins

This safety section lists basic safety precautions. distributor can assist you in adjusting your
In addition , this section identifies hazardous, maintenance schedule to meet the needs of your
warning situations . Read and understand the basic operating environment.
precautions listed in the safety section before
operating or performing lubrication , maintenance and
repair on this product. Overhaul
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Major engine overhaul details are not covered in

Operation the Operation and Maintenance Manual except
for the interval and the maintenance items in that
Operating techniques outlined in this manual are interval. Major repairs should only be carried out by
basic. They assist with developing the skills and Perkins authorized personnel. Your Perkins dealer
techniques required to operate the engine more or your Perkins distributor offers a variety of options
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efficiently and economically. Skill and techniques regarding overhaul programs. If you experience
develop as the operator gains knowledge of the a major engine failure, there are also numerous
engine and its capabilities. after failure overhaul options available. Consult with
your Perkins dealer or your Perkins distributor for
The operation section is a reference for operators . information regarding these options .
Photographs and illustrations guide the operator
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through procedures of inspecting , starting, operating

and stopping the engine. This section also includes a California Proposition 65 Warning
discussion of electronic diagnostic information.
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
Maintenance birth defects, and other reproductive harm. Battery
posts , terminals and related accessories contain lead
The maintenance section is a guide to engine care. and lead compounds. Wash hands after handling.
The illustrated , step-by-step instructions are grouped
by service hours andlor calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
SEBU7833-01 5
Safety Section
Safety Messages
Safety Section Ether

The warning label for ether is located on the top, the
i02206606 front, the rear, or the side of the engine .
Safety Messages
A. WARNING
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There may be several specific warning signs on
an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiar with all warning
signs.
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Ensure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if
the words cannot be read or if the pictures are not
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visible. When the warning signs are cleaned, use a
g00640926
cloth, water, and soap. Do not use solvent, gasoline,
or other harsh chemicals to clean the warning signs.
Never spray Ether starting aids into the air intet.
Solvents, gasoline , or harsh chemicals could loosen
the adhesive that secures the warning signs. The
warning signs that are loosened could drop off of
the engine.
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General Hazard Information
i02203039
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Replace any damaged warning signs or missing
warning signs. If a warning sign is attached to a part
of the engine that is replaced, install a new warning
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sign on the replacement part. Perkins dealers or

Perkins distributors can provide new warning signs.
Do not work on the engine and do not operate the

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

result in injury or in death.
The warning labels that may be found on the engine

are illustrated and described.
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Illustration 1 g00104545
Attach a "Do Not Operate" warning tag or a similar

warning tag to the start switch or to the controls
before you service the equipment or before you
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repair the equipment.

6 SEBU7833-01
Safety Section
General Hazard Information
The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi). The maximum
a , .
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water pressure for cleaning purposes must be below
275 kPa (40 psi) .
(i) 'd Fluid Penetration
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Pressure can be trapped in the hydraulic circuit long
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after the engine has been stopped . The pressure can
~ cause hydraulic fiuid or items such as pipe plugs to
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escape rapidly ifthe pressure is not relieved correctly.
ee> Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
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Illustration 2 900702020 may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
Wear a hard hat, protective glasses, and other or personal injury may occur. Refer to the OEM
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protective equipment, as requ ired . information for any procedures that are required to
relieve the hydraulic pressure .
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the engine .
Make sure that all protective guards and all covers

are secured in place on the engine.
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Keep the engine free from foreign material. Remove
debris, oil, tools, and other items from the deck, from
walkways, and from steps.
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Never put maintenance fluids into glass containers.

Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Illustratio n 3 g0068760 0
Use all cleaning solutions with care. Report all
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necessary repairs.
Always use a board or cardboard when you check
Do not allow unauthorized personnel on the for a leak. Leaking fluid that is under pressure can
equipment. penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
Note: Ensure that the power supply is disconnected cause severe injury. If fiuid is injected into your skin ,
you must get treatment immediately. Seek treatment
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before you work on the bus bar or the glow plugs .

from a doctor that is familiar with this type of injury.
Unless you are instructed otherwise, perform
maintenance on the engine with the equipment in Containing Fluid Spillage
the servicing position . Refer to the OEM information
for the procedure for placing the equipment in the Care must be taken in order to ensure that fluids
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servicing position . are contained du ring performance of inspection ,

maintenance, testing , adjusting and repair of the
Pressure Air and Water engine. Make provision to collect the fiuid with a
suitable container before any compartment is opened
Pressurized air and/or water can cause debris or before any component is disassembled.
and/or hot water to be blown out. This could result in
personal injury. • Only use the tools that are suitable for collecting
fluids and equipment that is suitable for collecting
When pressurized air and/or water is used for fluids.
cleaning , wear protective clothing , protective shoes,
and eye protection . Eye protection includes goggles • Only use the tools that are su itable for containing
or a protective face shield. fluids and equipment that is suitable for containing
fluids .
SEBU7833-01 7
Safety Section
Burn Prevention
Obey all local regulations for the disposal of liquids. i02203164
Fire Prevention and Explosion

i02143195
Prevention
Burn Prevention
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Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system , in the hydraulic system, in the
lubrication system, in the fuel system , or in the
cooling system before any lines , fittings or related
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items are disconnected.
Coolant
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When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or Illustration 4 900704000
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause

severe burns . Allow cooling system components to E
All fuels, most lubricants , and some coolant mixtures
are flammable.
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cool before the cooling system is drained. Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
Check the coolant level after the engine has stopped a fire. Fire may cause personal injury and property
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and the engine has been allowed to cool. damage.

Ensure that the filler cap is cool before removing the A flash fire may result if the covers for the engine
filler cap. The filler cap must be cool enough to touch crankcase are removed within fifteen minutes after
with a bare hand. Remove the filler cap slowly in an emergency shutdown.
order to relieve pressure.
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Determine whether the engine will be operated in an

Cooling system conditioner contains alkali. Alkali can environment that allows combustible gases to be
cause personal injury. Do not allow alkali to contact drawn into the air inlet system. These gases could
the skin, the eyes, or the mouth. cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Oils
If the application involves the presence of combustible
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Hot oil and hot lubricating components can cause gases, consult your Perkins dealer andlor your
personal injury. Do not allow hot oil to contact the Perkins distributor for additional information about
skin. Also, do not allow hot components to contact suitable protection devices.
the skin.
Remove all flammable combustible materials or
conductive materials such as fuel , oil , and debris from
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Batteries the engine. Do not allow any flammable combustible

materials or conductive materials to accumulate on
Electrolyte is an acid. Electrolyte can cause personal the engine.
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing Store fuels and lubricants in correctly marked
batteries. Wash hands after touching the batteries containers away from unauthorized persons . Store
and connectors. Use of gloves is recommended . oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.

8 SEBU7833-01
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 .
Do not weld on lines or tanks that conta in flammable

fluids . Do not flame cut lines or tanks that contain
flammable fluid . Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
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welding or flame cutting .
Wiring must be kept in good condition. All electrical

wires must be correctly routed and securely attacheo .
Check all electrical wires daily. Repair any wires
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that are loose or frayed before you operate the
engine . Clean all electrical connections and tighten
all electrical connections.
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Eliminate all wiring that is unattached or unnecessary.
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
Arcing or sparking could cause a fire . Secure

connections , recommended wiring , and correctly
maintained battery cables will help to prevent arcing E
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g00 704 135
Illustration 6
or sparking.
Gases from a battery can explode. Keep any open
Inspect all lines and hoses for wear or for
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flames or sparks away from the top of a battery. Do

deterioration. The hoses must be correctly routed .
not smoke in battery charging areas.
The lines and hoses must have adequate support
and secure clamps . Tighten all connections to the
Never check the battery charge by placing a metal
recommended torque. Leaks can cause fires.
object across the terminal posts. Use a voltmeter or
a hydrometer.
Oil filters and fuel filters must be correctly installed.
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The filter housings must be tightened to the correct

Incorrect jumper cable connections can cause
torque.
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause an

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explosion.
The batteries must be kept clean. The covers

(if equipped) must be kept on the cells. Use the
recommended cables, connections , and battery box
covers when the engine is operated .
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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
Illu stration 5
SEBU7833-01 9
Safety Section
Crushing Prevention and Cutting Prevention
Lines, Tubes and Hoses Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
Do not bend high pressure lines. Do not strike high one will be injured by flying debris.
pressure lines. Do not install any lines that are bent
or damaged.
i01372247
Repair any lines that are loose or damaged. Leaks

can cause fires . Consu lt your Perkins dealer or your
Mounting and Dismounting
Perkins distributor for repair or for replacement parts.
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Check lines, tubes and hoses carefully. Do not use Inspect the steps, the hand holds, and the work area
your bare hand to check for leaks. Use a board or before mounting the engine. Keep these items clean
cardboard to check for leaks. Tighten all connections and keep these items in good repair.
to the recommended torque.
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Mount the engine and dismount the engine only at
Replace the parts if any of the following conditions locations that have steps and/or handholds. Do not
are present: climb on the engine, and do not jump off the engine.
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• End fittings are damaged or leaking . Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
Outer coverings are chafed or cut. with the steps and handholds . Use two feet and one
hand or use one foot and two hands . Do not use any
Wires are exposed .
• Outer coverings are ballooning .

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controls as handholds.
Do not stand on components which cannot support

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your weight. Use an adequate ladder or use a work
• Flexible part of the hoses are kinked . platform . Secure the climbing equipment so that the
equipment will not move .
• Outer covers have embedded armoring .
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Do not carry tools or supplies when you mount the

• End fittings are displaced. engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation , this
will help to prevent vibration, rubbing against other i021 57341
parts, and excessive heat.
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Before Starting Engine

i021431 94
Crushing Prevention and NOTICE

Cutting Prevention For initial start-up of a new or rebuilt engine , and for
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start-up of an engine that has been serviced , make

provision to shut the engine off should an overs peed
occur. This may be accomplished by shutting off the
Support the component correctly when work beneath air and/or fuel supply to the engine .
the component is performed .
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Unless other maintenance instructions are provided , Overspeed shutdown should occur automatically.
never attempt adjustments while the engine is If automatic shutdown does not occur, press the
running . emergency stop button in order to cut the fuel and/or
air to the engine .
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance Inspect the engine for potential hazards.
is performed . After the maintenance is performed ,
reinstall the guards. Before starting the engine, ensure that no one is on ,
underneath , or close ·to the engine. Ensure that the
Keep objects away from moving fan blades. The fan area is free of personnel.
blades will throw objects or cut objects.
If equipped , ensure that the lighting system for the
When objects are struck, wear protective glasses in engine is suitable for the conditions . Ensure that all
order to avoid injury to the eyes. lights work correctly, if equipped.
I' 10 SEBU7833-01
Safety Section
Eng ine Starting
All protective guards and all protective covers must Note: The engine is equipped with an automatic
be installed if the engine must be started in order device for cold starting for normal conditions of
to perform service procedures. To help prevent an operation . If the engine will be operated in very cold
accident that is caused by parts in rotation , work conditions , then an extra cold starting aid may be
around the parts carefully. required . Normally, the engine will be equipped with
the correct type of starting aid for your region of
Do not bypass the automatic shutoff circuits. Do not operation .
disable the automatic shutoff circuits . The circuits are
provided in order to help prevent personal injury. The The engines are equipped with a glow plug starting
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circuits are also provided in order to help prevent aid in each individual cylinder that heats the intake
engine damage. air in order to improve starting.
See the Service Manual for repairs and for

i01928905
adjustments .
Engine Stopping
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102207232
Engine Starting
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Stop the engine according to the procedure in
the Operation and Maintenance Manual, "Engine
Stopping (Operation Section)" in order to avoid
overheating of the engine and accelerated wear of
A WARNING
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and E the engine components.
Use the Emergency Stop Button (if equipped) ONLY

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in an emergency situation. Do not use the Emergency
personal injury.
Stop Button for normal engine stopping . After an
emergency stop, DO NOT start the engine until the
If a warning tag is attached to the engine start switch problem that caused the emergency stop has been
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or to the controls , DO NOT start the engine or move corrected.

the controls . Consult with the person that attached
the warning tag before the engine is started . Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine
All protective guards and all protective covers must that has been overhauled. This may be accomplished
be installed if the engine rnust be started in order by shutting off the fuel supply to the engine and/or
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to perform service procedures. To help prevent an shutting off the air supply to the engine.
accident that is caused by parts in rotation , work
around the parts carefully.
i02176668
Start the engine from the operator's compartment or Electrical System

from the engine start switch .
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Always start the engine according to the procedure

that is described in the Operation and Maintenance Never disconnect any charging unit circuit or battery
Manual, "Engine Starting" topic in the Operation circuit cable from the battery when the charging unit
Section . Knowing the correct procedure will help to is operating. A spark can cause the combustible
prevent major damage to the engine components . gases that are produced by some batteries to ignite.
Knowing the procedure will also help to prevent
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personal injury. To help prevent sparks from igniting combustible

gases that are produced by some batteries, the
To ensure that the jacket water heater (if equipped) negative "-" jump start cable should be connected
and/or the lube oil heater (if equipped) is working last from the external power source to the negative
correctly, check the water temperature gauge and the "-" terminal of the starting motor. If the starting motor
oil temperature gauge during the heater operation . is not equipped with a negative "- " terminal, connect
the jump start cable to the engine block.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside .
SEBU7833-01 11
Safety Section
Electrical System
Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started . See
the Operation and Maintenance Manual for specific
starting instructions.
Grounding Practices
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Correct grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
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Uncontrolled electrical circuit paths can result in
damage to main bearings , to crankshaft bearing
journal surfaces, and to aluminum components.
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Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
To ensure that the engine and the engine electrical

systems function correctly, an engine-to-frame
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ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine ground to the frame.
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All grounds should be tight and free of corrosion. The

engine alternator must be grounded to the negative
"-" battery terminal with a wire that is adequate to
handle the full charging current of the alternator.
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12 SEBU7833-
Model Views
Product Information
Section
Model Views
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i01928892
Model View Illustrations
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1104 Engine Model Views
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---.!!J-i--- 2
3
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9
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90 1012
Illustration 7
(1) Valve mechanism cover (4) Fuel injection pump (7) Water pump
(2) Crankcase breather (5) Engi ne oil filter (8) Fan pull ey
(3) Fuel fi lter (6) Crankshaft pulley (9) Water temperatu re regu lator hous ing
SEBU7833-01 13
Model Views
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2
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8
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3
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g01012281
Illustration 8
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(1) Oil filler cap (5) Starter motor

(2) Exhaust manifold (6) Flywheel housing
(3) Alternator (7) Flywheel
(4) Turbocharger (8) Air intake
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•
I I 14
Model Views
SEBU7833-01
1103 Engine Model Views
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Illustration 9 g01 011348
(1 ) Alternator (3) Turbocharger oil supply (5) Turbocharger

(2) Fan pulley (4) Turbocharger oil drain (6) exhaust manifold
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SEBU7833-01 15
Product tnformation Section
Model Views
10
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g01011349
Illu stration 10
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(1) Fuel transfer pump (6) Oil filter

(2) Oi l filler cap (7) Oil pan
(3) Fuel filter (8) Cra nks haft pulley
(4) Starter motor (9) Water pump
(5) Dipstick (10) Water temperature regu la tor housing
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i02196981 • Naturally aspirated
Engine Description
Engine Specifications
Note: The front end of the engine is opposite the
Perkins Engines are designed for the following flywheel end of the eng ine. The left and the right
applications : machine, genset, and industrial mobile sides of the engine are determined from the flywheel
equipment. The engines are available in the following end . The number 1 cylinder is the front cylinder.
types of aspiration:
• Turbocharged aftercooled
• Turbocharged
16 SEBU7833-01
Model Views
Table 2
1103 Industrial Engine Specificalions

,---- Number of Cylinders 3 In-Line
Bore 105 mm (4.134 inch)
1 2 3 4
f ~~~~
Stroke 127 mm (5.0 inch)
Aspiration Turbocharged
Naturally aspirated
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Compression Ratio NA 19.25:1
-
o
A
•B Displacement
T 18.25:1
3.3 L (201 in')
Firing Order 123
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g00984281
Illustration 11
Rotation (flywheel end) Counterclockwise
A typical example of the layout of the valves
(A) Inlet valves Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
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(8) Exhaust valves
Valve Lash Setting 0.45 mm (0.018 inch)
(Exhaust)
Table 1
1104 Industrial Engine Specifications

Table 3
Number of Cylinders
Bore
4 In-Line
105 mm (4 .134 inch)
E 1104 Genset Specifications
Number of Cylinders 4 In-Line
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Stroke 127 mm (5.0 inch) Bore 105 mm (4.134 inch)
Aspiration Turbocharged aftercooled Stroke 127 mm (5.0 inch)
Turbocharged
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Naturally aspirated Aspiration Turbocharged aftercooled

Turbocharged
Compression Ratio NA 19.25:1 NA Naturally aspirated
T 18.23:1 T, TA
Compression Ratios NA 19.25:1
Displacement 4.4 L (268 in ') T 17.25:1, T 18.23:1,
Firing Order 13 4 2 TA 18.23:1
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Rotation (flywheel end) Counterclockwise Displacement 4.4 L (268 in ' )
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Firing Order 1 34 2
Valve Lash Setting Rotation (flywheel end) Counterclockwise

0.45 mm (0.018 inch)
(Exhaust) Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
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Valve Lash Setting

0.45 mm (0 .018 inch)
I I (Exhaust)
I
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SEBU7833-01 17
Model Views
Tab le 4 Engine Service Life

1103 Genset Specifications
Engine efficiency and maximum utilization of engine
Number of Cylinders 3 In-Line performance depend on the adherence to proper
operation and maintenance recommendations. In
Bore 105 mm (4.134 inch)
addition , use recommended fuels, coolants and
Stroke 127 mm (5.0 inch) lubricants, Use the Operation and Maintenance
Manual as a guide for required engine maintenance,
Aspiration Turbocharged
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Naturally aspirated
Expected engine life is generally predicted by the
Compression Ratio NA 19.25:1 average power that is demanded, The average power
T 17.25:1 that is demanded is based on fuel consumption of
Displacement 3.3 L (201 in' ) the engine over a period of time, Reduced hours of
operation at full throttle and/or operating at reduced
123
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Firing Order throttle settings result in a lower average power
Rotation (flywheel end) Counterclockwise demand , Reduced hours of operation will increase
the length of operating time before an engine
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) overhaul is required.
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Valve Lash Setting 0.45 mm (0,018 inch)
(Exhaust)
Engine Cooling and Lubrication

The cooling system consists of the following
E
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components:
• Gear-driven centrifugal water pump

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• Water temperature regulator which regulates the

engine coolant temperature
• Gear-driven oil pump (gear type)
• Oil cooler
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The engine lubricating oil is supplied by a gear

type pump, The engine lubricating oil is cooled and
the engine lubricating oil is filtered. Bypass valves
provide unrestricted flow of lubrication oil to the
engine parts when oil viscosity is high, Bypass valves
can also provide unrestricted flow of lubrication oil
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to the engine parts if the oil cooler should become

plugged or if the oil filter element should become
plugged.
Engine efficiency, efficiency of emission controls , and

engine performance depend on adherence to proper
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operation and maintenance recommendations,

Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
coolants , Refer to the Operation and Maintenance
Manual, "Maintenance Interval Schedule" for more
information on maintenance items.
18 SEBU7833-01
I Product Information Section

Product Identification Information
Product Identification The Serial Number Plate is located on the left side of
the cylinder block behind the high pressure pipes of
Information the Fuel injection pump .
The following information is stamped on the Serial

i0 1940475 Number Plate : Engine serial number, Model , and
Arrangement number.
Engine Identification
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i02 164876
Perkins engines are identified by a serial number. Reference Numbers

This number is shown on a serial number plate that
is mounted on the left hand side of the engine block.
Information for the following items may be needed to
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An example of an engine number is REU090001 H.
order parts. Locate the information for your engine.
RE _ _ _ _ _ __ _ _ _ _ _Type of engine Record the information in the appropriate space .
Make a copy of this list for a record . Keep the
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U _ _ _ _ _ _ _ _ _Built in the United Kingdom information for future reference.
0900001 _ _ _ _ _ _ _ _ Engine Serial Number

Record for Reference
H _ _ _ _ _ _ _ _ _ _ _ year of Manufacture
Perkins dealers need these numbers in order to

determine the components that were included with E Engine Model _ _ _ _ _ _ _ _ _ _ _ _ __
Engine Serial number _ _ _ _ _ _ _ _ _ __

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the engine . This permits accurate identification of Engine Low Idle rpm _ _ _ _ _ _ _ _ _ _ __
replacement part numbers.
Engine Full Load rpm _ _ _ _ _ _ _ _ _ __
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i0 1940474
Primary Fuel Filter _ _ _ _ _ _ _ _ _ _ __
Serial Number Plate
Water Separator Element _ _ _ _ _ _ _ _ __
Secondary Fuel Filter Element _ _ _ _ _ _ __

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Lubrication Oil Filter Element _ _ _ _ _ _ _ __
Auxiliary Oil Filter Element _ _ _ _ _ _ _ _ __
i!8perklnsl ]EJIIGIAI'm ~ j- 1 Total Lubrication System Capacity _ _ _ _ _ __

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o 0
Total Cooling System Capacity _ _ _ _ _ _ __
l~ gl~ r:t Air Cleaner Element _ _ _ _ _ _ _ _ _ _ __
4 3 2
Fan Drive Belt _ _ _ _ _ _ _ _ _ _ _ _ __
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Alternator Belt _ _ _ _ _ _ _ _ _ _ _ _ __
i02197956
Emissions Certification Film
Illustration 12 900994966
Typical serial number plate

Label for compliant engines
(1 ) Temporary Parts List number
(2) Type
(3) Serial number
Examples of emissions labels
(4) list number
SEBU7833-01 19
Product Identifi cation Information
IMPORTANT ENGINE INFORMATION UPerkins

Engine Family: 3PKXL04 .0AJ1 Lis!: AP31478
Engine Type: 5633/2200 Displacement: 3.990
Advertised kw:50. 0 @ RPM : 2200
C9 Refer to
Manufacturer
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Fuel Rate at adv kw: 56.0 mm31stk
I nit. Timing:3 DEG BTDC idle RPM: 1000 ell*97/68CA"00"000*0089"01
Settings are to be made with engine at normal operating temperature

with transmission in neutral. This engine conforms to 2003 U.S. EPA
non - road and California off - road Regulations for large C.1. engines
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and is certified to operate on commercially available diesel fuel.
Emission C ontrol System:
001
I Valve Lash Cold (inch):
Exhaust 0.018 Inlet 0.008
I
Engine Label
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Hanger No. position Label No . 3181A081
Illu stration 13 901127835
This label is installed on engines that comply with emissions.
Label for engines that are not E

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compliant
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EMISSIONS CONTROL INFORMATION UPerkins

ENGINE FAMILY : Text2 MODEL YEAR: 2003
ENGINE DISPLACEMENT : 6. 0
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INFORMATION APPLICABLE TO USA ONLY

This non - road engine does not comply with either federal non - road or
California off - road engine emission regulation requirements. Sale or
installation of this engine is a violation of federal and Californian
law subject to civil penalty for any purpose other than as an
EXPORT - ONLY or REPLACEMENT engine
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Export - only engine is indicated by an additional attached tag

Replacement engine is for an engine manufactured prior to 1 Jan 2004
Label No . 3181A081
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g0 1119323
Illustration 14
Th is label is installed on engines that have a variable speed. These engi nes do not com ply with emissions.
20 SEBU7833-01
Product Identification Information
EMISSIONS CONTROL INFORMATION ~Perkfns
ENGINE FAMILY: 1104C -44TA MODEL YEAR: 2003

ENGINE DISPLACEMENT: 4. 400
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FOLLOWING INFORMATION APPLICABLE TO USA ONLY
This non - road engine does not comply with either federal non - road
or California off - road engine emission regulation requirement.
Sale or installation of this engine can only be for
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STATIONARY ENGINE
Use only as defined by CFR 40 PART 89.2.
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Hanger No Position (81) Label 318A081
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This label is installed on engines that have a fixed speed . These engines do not comply with emissions.
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SEBU7833-01 21
Operation Section
Lifting and Storage
Operation Section Some removals require lifting the fixtures in order to

obtain correct balance and safety.
To remove the engine ONLY, use the lifting eyes that

Lifting and Storage are on the engine.
Lifting eyes are designed and installed for specific

1021 64186 engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
Engine Lifting
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fixtures obsolete. If alterations are made, ensure
that correct lifting devices are provided . Consult
your Perkins dealer or your Perkins distributor for
information regarding fixtures for correct engine
lifting.
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10 1930351
Engine Storage
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o o o
If the engine will not be started for several weeks , the
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lubricating oil will drain from the cylinder walls and
from the piston rings . Rust can form on the cylinder
walls. Rust on the cylinder walls will cause increased
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engine wear and a reduction in engine service life.
Lubrication System
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To help prevent excessive engine wear, use the

following guidelines :
Complete all of the lubrication recommendations that

are listed in this Operation and Maintenance Manual,
"Maintenance Interval Schedule" (Maintenance
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Section).
If an engine is out of operation and if use of the engine

is not planned , special precautions should be made.
g01097527
Illustration 16 If the engine will be stored for more than one month ,
a complete protection procedure is recommended .
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NOTICE
Never bend the eyebolts and the brackets. Only load Use the following guidelines:
the eyebolts and the brackets under tension . Remem-
ber that the capacity of an eyebolt is less as the angle • Completely clean the outside of the engine.
between the supporting members and the object be-
comes less than 90 degrees. • Drain the fuel system completely and refill
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the system with preservative fue1.1772204

When it is necessary to remove a component at an POWERPART Lay-Up 1 can be mixed with
angle, only use a link bracket that is properly rated for the normal fuel in order to change the fuel into
the weight. preservative fuel.
• If preservative fuel is not available , the fuel system

Use a hoist to remove heavy components . Use can be filled with normal fuel. This fuel must be
an adjustable lifting beam to lift the engine. All discarded at the end of the storage period together
supporting members (chains and cables) should be with the fuel filter elements .
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being • Operate the engine until the engine reaches
lifted. normal operating temperature. Stop any leaks from
fuel , lubricating oil or air systems. Stop the engine
and drain the lubricating oil from the oil pan .
II 22 SEBU7833-01
Operation Section
Lifting and Storage
• Renew the canister(s) of the lubricating oil filter. 4. Open the tap or remove the drain plug at the
bottom of the radiator in order to drain the radiator.
• Fill the oil pan to the Full Mark on the dipstick If the radiator does not have a tap or a drain plug ,
with new, clean lubricating oil. Add 1762811 disconnect the hose at the bottom of the radiator.
POWERPART Lay-Up 2 to the oil in order to
protect the engine against corrosion. If 1762811 5. Flush the cooling system with clean water.
POWERPART Lay-Up 2 is not available , use a
preservative of the correct specification instead 6. Fit the drain plugs and the filler cap . Close the tap
of the lubricating oil. If a preservative is used, or connect the radiator hose.
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this must be drained completely at the end of the
storage period and the oil pan must be refilled to 7. Fill the cooling system with an approved
the correct level with normal lubricating oil. antifreeze mixture because this gives protection
against corrosion . The maximum flow rate is 1 L
Cooling System (0.2200 Imp gal) per minute in order to fill the
system.
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To help prevent excessive engine wear, use the
following guidelines: Note: Certain corrosion inhibitors could cause
damage to some engine components. Contact the
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Service Department of Perkins for advice.
NOTICE
Do not drain the coolant while the engine is still hot and 8. Operate the engine for a short period in order to
the system is under pressure because dangerous hot circulate the lubricating oil and the coolant in the
coolant can be discharged. engine .
If freezing temperatures are expected, check the

cooling system for adequate protection against E 9. Disconnect the battery. Put the battery into safe
storage in a fully charged condition. Before the
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freezing. See this Operation and Maintenance battery is put into storage, protect the terminals
Manual , "General Coolant Information" (Maintenance against corrosion.1734115 POWERPART Lay-Up
3 can be used on the terminals.
Section).
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10. Clean the crankcase breather if one is installed.

NOTICE Seal the end of the pipe.
To prevent frost damage , ensure that all the coolant is
removed from the engine. This is important if the sys- 11. Remove the fuel injector nozzles and spray
tem is drained after it has been flushed with water, or if 1762811 POWERPART Lay-Up 2 for one or two
an antifreeze solution too weak to protect the system seconds into each cylinder bore with the piston
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from frost has been used. at BDC .
u 12. Slowly rotate the crankshaft for one complete

revolution and then replace the fuel injector
nozzles.
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Induction System
,0 • 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
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turbocharger. The duration of the spray is printed

on the con ta iner. Seal the turbocharger with
waterproof tape.
Exhaust System
1. Ensure that the vehicle is on level ground .
Remove the exhaust pipe. Spray 1762811
2. Remove the filler cap of the cooling system. POWERPART Lay-Up 2 into the turbocharger. The
duration of the spray is printed on the container.
3. Remove the drain plug (1) from the side of the Seal the turbocharger wi th waterproof tape.
cylinder block in order to drain the engine. Ensure
that the drain hole is not restricted .
SEBU7833-01 23
Operation Section
Lifting and Storage
General Items
If the lubricating oil filler is installed on the rocker
cover, remove the filler cap. If the lubricating oil filler
cap is not installed on the rocker cover, remove
the rocker cover. Spray 1762811 POWERPART
Lay-Up 2 around the rocker shaft assembly.
Replace the filler cap or the rocker cover.
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• Seal the vent of the fuel tank or the fuel filler cap
with waterproof tape.
• Remove the alternator drive belts and put the drive

belts into storage.
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• In order to prevent corrosion, spray the engine with
1 73411 5 POWERPART Lay-Up 3. Do not spray
the area inside the alternator.
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When the engine protection has been completed in
accordance with these instructions, this ensures that
no corrosion will occur. Perkins are not responsible
for damage which may occur when an engine is in
storage after a period in service.
Your Perkins dealer or your Perkins distributor can E

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assist in preparing the engine for extended storage
periods.
EN
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24 SEBU7833-01
Operation Section
Gauges and Indicators
Gauges and Indicators 1. Reduce the load and the engine rpm.
2. Inspect the cooling system for leaks.

i02164190
3. Determine if the engine must be shut down
Gauges and Indicators immediately or if the engine can be cooled by
reducing the load.
cw Tachometer - This gauge indicates engine
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Your engine may not have the same gauges or all of
the gauges that are described . For more information
Jj speed (rpm). When the throttle control lever
is moved to the full throttle position without
about the gauge package, see the OEM information. load, the engine is running at high idle. The engine is
running at the full load rpm when the throttle control
Gauges provide indications of engine performance. lever is at the full throttle position with maximum
Ensure that the gauges are in good working order.
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rated load .
Determine the normal operating range by observing
the gauges over a period of time .
NOTICE
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Noticeable changes in gauge readings indicate To help prevent engine damage , never exceed the
potential gauge or engine problems . Problems may high idle rpm . Overspeedi ng can result in serious
also be indicated by gauge readings that change damage to the engine. The engine can be operated
even if the readings are within specifications. at high idle without damage, but should never be
Determine and correct the cause of any significant allowed to exceed high idle rpm.
or your Perkins distributor for assistance.

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change in the readings. Consult your Perkins dealer
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Ammeter - This gauge indicates the
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amount of charge or discharge in the
NOTICE battery charging circuit. Operation of the
If no oil pressure is indicated, STOP the engine. If indicator should be to the right side of "0" (zero).
maximum coolant temperature is exceeded, STOP
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the engine. Engine damage can result.

(J)~
Fuel Level - This gauge indicates the fuel
• level in th e fuel tank. The fuel level gauge
Engine Oil Pressure - The oil pressure operates when the "START/STOP" switch
@)
+<l>+ should be grealest after a cold engine is
started. The typical engine oil pressure with
is in the "ON" position .
SAE10W30 is 207 to 413 kPa (30 to 60 psi) at rated Service Hour Meter - The gauge indicates
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rpm . operating time of the engine.
A lower oil pressure is normal at low idle. If the load

is stable and the gauge reading changes, perform
the following procedure:
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1. Remove the load.
2. Reduce engine speed to low idle.
3. Check and maintain the oil level.

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' JaCketWatercootantTemperature-
@'i! Typical temperature range is 71 to 96"C
(160 to 205"F). The maximum allowable
temperature with the pressurized cooling system at
48 kPa (7 psi) is 11 O"C (230"F). Higher temperatures
may occur under certain cond itions. The water
temperature reading may vary accord ing to load. The
reading should never exceed the boiling point for the
pressurized system that is being used.
If the engine is operating above the normal range

and steam becomes apparent, perform the fol lowing
procedure:
SEBU7833-01 25
Operation Section
Engine Starting
Engine Starting Do not start the engine or move any of the controls
if there is a "DO NOT OPERATE" warning tag or
similar warning tag attached to the start switch or
i0 2194223 to the controls .
Before Starting Engine • Ensure that the areas around the rotating parts are
clear.
• All of the guards must be put in place. Check for
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Before the engine is started, perform the required damaged guards or for missing guards . Repair
daily maintenance and any other periodic any damaged guards. Replace damaged guards
maintenance that is due. Refer to the Operation and/or missing guards.
and Maintenance Manual, "Maintenance Interval
Schedule" for more information. • Disconnect any battery chargers that are not
protected against the high current drain that
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For the maximum service life of the engine, make a is created when the electric starting motor is
thorough inspection within the engine compartment engaged . Check electrical cables and check the
before the engine is started. Look for the following battery for poor connections and for corrosion.
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items: oil leaks, coolant leaks, loose boits, and
excessive dirt and/or grease. Remove any excess • Reset all of the shutoffs or alarm components (if
dirt and/or grease buildup. Repair any faults that equipped) .
were identified during the inspection .
• Check the engine lubrication oil level. Maintain the
Inspect the cooling system hoses for cracks and
for loose clamps .
E oil level between the "ADD" mark and the "FULL"
mark on the engine oil level gauge.
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• 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
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• 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 .
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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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• Ensure that any equipment that is driven by the

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

Manual , "Fuel System - Prime" for more information
on priming the fuel system.
A WARNING
Engine exhaust contains products of combustion
which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
26 SEBU7833-01
Operation Section
Engine Starting
i02198348 When Group 2 diesel fuel is used , the following items

provide a means of minimizing starting problems
Starting the Engine and fuel problems in cold weather: engine oil pan
heaters, jacket water heaters, fuel heaters , and fuel
line insulation.
A WARNING
Use the procedure that follows for cold weather
starting .
Do not use aerosol types of starting aids such as
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ether. Such use could result in an explosion and 1. If equipped, move the throttle lever to the full
personal injury. throttle position before you start the engine .
2, If equipped , turn the engine start switch to the

Refer to the OMM for your type of controls. Use the HEAT position . Hold the engine start switch in the '
following procedure to start the engine. HEAT position for 6 seconds until the glow plug
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indicator light illuminates. This will activate the
1. If equipped , move the throttle lever to the full glow plugs and aid in the starting of the engine.
throttle position before you start the engine.
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NOTICE
NOTICE Do not crank the engine for more than 30 seconds.
Do not crank the engine for more than 30 seconds. Allow the electric starting motorto cool for two minutes
Allow the electric starting motor to cool for two minutes before cranking the engine again.
before cranking the engine again .
E
2. Turn the engine start switch to the START position .
3. While the glow plug indicator light is illuminated ,
turn the engine start switch to the START position
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Hold the engine start switch in the START position and crank the engine .
and crank the engine.
Note: If the glow plug indicator light illuminates
3. When the engine starts, release the engine start
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rapidly for 2 to 3 seconds, or if the glow plug indicator

switch. light fails to illuminate, a malfunction exists in the cold
start system . Do not use ether or other starting flu ids
4. If equipped , slowly move the throttle tever to the to start the engine.
low idle position and allow the engine to idle. Refer
to the Operation and Maintenance Manual, "After 4. When the engine starts , release the engine start
Starting Engine" topic. switch key.
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5. If the engine does not start, release the engine 5. If the engine does not start, release the engine
start switch and allow the electric starting motor to start switch and allow the starter motor to cool.
cool. Then, repeat steps 2 through step 4. Then , repeat steps 2 through step 4.
6. Turn the engine start switch to the OFF position in 6. If the engine is equipped with a throttle allow the
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order to stop the engine. engine to idle for three to five minutes, or allow the
engine to idle until the water temperature indicator
begins to rise . The engine should run at low idle
i02198092
smoothly until speed is gradually increased to high
Cold Weather Starting idle. Allow the white smoke to disperse before
proceeding with normal operation .
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7. Operate the engine at low load until all systems

reach operating temperature. Check the gauges
A WARNING during the warm-up period.
Do not use aerosol types of starting aids such as 8. Turn the engine start switch to the OFF position in
ether. Such use coutd resutt in an exptosion and order to stop the engine.
personat injury.
Startabilily will be improved at temperatures below

-18 'C (0 ' F) from the use of a jacket water heater
or extra battery capacity.
SEBU7833-01 27
Operation Section
Engine Starting
i021 77935 3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical
Starting with Jump Start source . Connect the other negative end of the
Cables jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting the combustible
gases that are produced by some batteries.
A WARNING 4. Start the engine.
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Improper jump start cable connections can cause 5. Immediately after the stalled engine is started,
an explosion resulting in personal injury. disconnect the jump start cables in reverse order.
Prevent sparks near the batteries. Sparks could After jump starting , the alternator may not be able to
cause vapors to explode. Do not allow jump start fully recharge batteries that are severely discharged.
N
cable ends to contact each other or the engine. The batteries must be replaced or charged to the
correct voltage with a battery charger after the engine
Note: If it is possible. first diagnose the reason is stopped . Many batteries which are considered
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for the starting failure . Make any necessary unusable are still rechargeable. Refer to Operation
repairs . If the engine will not start only due to and Maintenance Manual, "Battery - Replace" and
the condition of the battery, either charge the Testing and Adjusting Manual, "Battery - Test".
battery, or start the engine with jump start cables.
The condition of the battery can be rechecked
after the engine has been switched OFF.
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After Starting Engine
i01903609
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NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for Note: In temperatures from 0 to 60°C (32 to 140°F),
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jump starting . The use of higher voltage will damage the warm-up time is approximately three minutes . In
the electrical system . temperatures below O°C (32 °F) , additional warm-up
time may be required .
Do not reverse the battery cables. The alternator can
be damaged . Attach ground cable last and remove When the engine idles during warm-up, observe the
first. following conditions :
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When using an external electrical source to start the Check for any fluid or for any air leaks at idle rpm
engine, turn the generator set control switch to the and at one-half full rpm (no load on the engine)
"OFF" position . Turn all electrical accessories OFF be- before operating the engine under load . This is not
fore attaching the jump start cables . possible in some applications .
Ensure that the main power switch is in the OFF posi- Operate the engine at low idle until all systems
EF
tion before attaching the jump start cables to the en- achieve operating temperatures . Check all gauges
gine being started . during the warm-up period .
Note: Gauge readings should be observed and

1. Turn the start switch to the OFF position. Turn off the data should be recorded frequently while the
all the engine's accessories . engine is operating . Comparing the data over time
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will help to determine normal readings for each

2. Connect one positive end of the jump start cable gauge. Comparing data over time will also help
to the positive cable terminal of the discharged detect abnormal operating developments. Significant
battery. Connect the other positive end of the jump changes in the readings should be investigated.
start cable to the positive cable terminal of the
electrical source.
28 SEBU7833-01
Operation Section
Engine Operation
Engine Operation i02164252
Fuel Conservation Practices

i02176671
Engine Operation
The efficiency of the engine can affect the fuel
economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
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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.
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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. Repai r the fuel lines, as needed.
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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.
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Gauge readings should be observed and the data
should be recorded frequently while the engine
is operating. Comparing the data over time will
Shut off the engine rather than idle for long periods of
time.
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help to determine normal readings for each gauge.
Comparing data over time will also help detect • Observe the service indicator frequently. Keep the
abnormal operating developments. Significant air cleaner elements clean.
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changes in the readings should be investigated.

• Maintain a good electrical system.
i01929404
One damaged battery cell will overwork the alternator.
Engine Warm-up This will consume excess power and excess fuel.
• Ensure that the drive belts are correctly adjusted.

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The drive belts should be in good condition .

1. Run the engine at low idle for three to five minutes,
or run the engine at low idle until the jacket water Ensure that all of the connections of the hoses are
temperature starts to rise. tight. The connections should not leak.
More time may be necessary when the • Ensure that the driven equipment is in good
EF
temperature is below -18°C (0° F). working order.
2. Check all of the gauges during the warm-up Cold engines consume excess fuel. Utilize heat
period. from the jacket water system and the exhaust
system, when possible. Keep cooling system
3. Perform a walk-around inspection. Check the components clean and keep cooling system
R
engine for fluid leaks and air leaks. components in good repair. Never operate the
engine without water temperature regulators .
4. Increase the rpm to the rated rpm . Check for All of these items will help maintain operating
fluid leaks and air leaks. The engine may be temperatures .
operated at full rated rpm and at full load when
the temperature of the water jacket reaches 60°C
(140°F)
SEBU7833-01 29
Operation Section
Engine Stopping
Engine Stopping i01 903608
After Stopping Engine

i0 1929389
Stopping the Engine

Note: Before you check the engine oil , do not operate
the engine for at least 10 minutes in order to allow
the engine oil to return to the oil pan .
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NOTICE
• Check the crankcase oil level. Maintain the oil level
Stopping the engine immediately after it has been
between the "ADD" mark and the "FULL" mark on
working under load can result in overheating and ac-
the oil level dipstick.
celerated wear of the engine components.
• If necessary, perform minor adjustments. Repair
If the engine has been operating at high rpm and/or
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any leaks and tighten any loose bolts .
high loads, run at low idle for at least three minutes
to reduce and stabilize internal engine temperature
Note the required service interval. Perform
before stopping the engine .
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the maintenance that is in the Operation and
Maintenance Manual, "Maintenance Interval
Avoiding hot engine shutdowns will maximize tur-
Schedule".
bocharger shaft and bearing life.
• Fill the fuel tank in order to help prevent
Prior to stopping an engine that is being operated
at low loads, operate the engine at low idle for 30
seconds before stopping. If the engine has been E accumulation of moisture in the fuel. Do not overfill
the fuel tank.
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operating at highway speeds and/or at high loads, NOTICE
operate the engine at low idle for at least three Only use antifreeze/coolant mixtures recommended in
minutes . This procedure will cause the internal the Coolant Specifications that are in the Operation
engine temperature to be reduced and stabilized.
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and Maintenance Manual. Failure to do so can cause

engine damage.
Ensure that the engine stopping procedure is
understood. Stop the engine according to the shutoff
system on the engine or refer to the instructions that • Allow the engine to cool. Check the coolant level.
are provided by the OEM.
If freezing temperatures are expected , check the
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• To stop the engine, turn the ignition key switch to coolant for the correct antifreeze protection. The
the OFF position. cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the correct coolanUwater mixture, if necessary.
i01903586
• Perform all required periodic maintenance on all
Emergency Stopping driven equipment. This maintenance is outlined in
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the instructions from the OEM .
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
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controls for normal stopping procedure.
The OEM may have equipped the application with

an emergency stop button . For more information
about the emergency stop button , refer to the OEM
information.
Ensure that any components for the external system

that support the engine operation are secured after
the engine is stopped.
30 SEBU7833-01
Operation Section
Cold Weather Operation
Cold Weather Operation Install the correct lubricant in each compartment

before the beginning of cold weather.
102200467 • Check all rubber parts (hoses , fan drive belts, etc)
weekly.
• Check all electrical wiring and connections for any
fraying or damaged insulation.
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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
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in snow.
• The viscosity of the engine oil
A WARNING
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• The operation of the glow plugs or the operation of
the air inlet heater
Personal injury or property damage can result
• Optional Cold starting aid from alcohol or starting fluids.
Alcohol or starting fluids are highly flammable and

information:
E
The purpose of this section will cover the following
toxic and if improperly stored could result in injury
or property damage.
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• Explain potential problems that are caused by cold
weather operation.
A WARNING
• Suggest steps which can be taken in order to
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minimize starting problems and operating problems Do not use aerosol types of starting aids such as
when the ambient air temperature is colder than ether. Such use could result in an explosion and
o to -55 °C (32 to -67 OF). personal injury.
The operation and maintenance of an engine in • For jump starting with cables in cold weather,
freezing temperatures is complex. This is because refer to the Operation and Maintenance Manual,
ER
of the following conditions: the unlimited differences "Starting with Jump Start Cables." for instructions.
in weather conditions, engine applications, and
the supplies that are available in your area. These
factors and recommendations from your Perkins Viscosity of the Engine Lubrication
dealer or your Perkins distributor are based on past Oil
proven practices. The information that is contained in
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this section should be combined in order to provide Correct engine oil viscosity is essential. Oil viscosity
guidelines for cold weather operations. affects the amount of torque that is needed to
crank the engine. Refer to this Operation and
Hints for Cold Weather Operation Maintenance Manual, "Fluid Recommendations" for
the recommended viscosity of oil.
• If the engine will start, operate the engine until a
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minimum operating temperature of 71 °C (160 OF) Recommendations for the Coolant

is achieved. Achieving operating temperature will
help prevent the intake valves and exhaust valves Provide cooling system protection for the lowest
from sticking . expected outside temperature. Refer to this Operation
and Maintenance Manual, "Fluid Recommendations"
• The cooling system and the lubrication system for the recommended coolant mixture.
for the engine do not lose heat immediately upon
shutdown. This means that an engine can be shut In cold weather, check the coolant often for the
down for a few hours and the engine can still have correct glycol concentration in order to ensure
the ability to start readily. If the engine is shut adequate freeze protection .
down for at least eight hours, the engine should be
considered cooled to outside temperature.
SEBU7833-01 31
Operation Section
Engine Block Heaters • Pushrods are bent.
Engine block heaters (if equipped) heat the • Other damage to valve train components can
engine jacket water that surrounds the combustion result.
chambers. This provides the following functions:
For this reason , when the engine is started ,
• Startability is improved. the engine must be operated until the coolant
temperature is 71 °C (160 OF) minimum. Carbon
• Warm up time is reduced. deposits on the valve stems will be kept at a minimum
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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
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extended. Lubrication will be improved. There will be
Idling the Engine less acid and less sludge in the oil. This will provide
longer service life for the engine bearings, the piston
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When idling after the engine is started in cold rings, and other parts. However, limit unnecessary
weather, increase the engine rpm from 1000 to 1200 idle time to ten minutes in order to reduce wear and
rpm. This will warm up the engine more quickly. unnecessary fuel consumption.
Maintaining an elevated low idle speed for extended
Purge Valve and Insulated Heater Lines
periods will be easier with the installation of a hand
throttle . The engine should not be "raced" in order to
speed up the warm up process.
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The engine is equipped with a water temperature
regulator in order to allow the engine to reach the
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While the engine is idling, the application of a light correct operating temperature quickly. The water
load (parasitic load) will assist in maintaining the temperature regulator remains in the closed position
minimum operating temperature. The minimum until the jacket water coolant temperature has
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operating temperature is 71 °C (160 OF) . reached the engine'S operating temperature . The
jacket water circulates from the top of the cylinder
block, to the water temperature regulator housing,
Recommendations for Coolant and back to the bottom of the cylinder block via the
Warm Up bypass. The water temperature regulator allows
some flow of water andlor air to pass through the
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Warm up an engine that has cooled below normal water temperature regulator in order to ensure a
operating temperatures due to inactivity. This should continuous flow of coolant within the cylinder block.
be performed before the engine is returned to full This is achieved via a small "jiggle" valve in the
operation . During operation in very cold temperature water temperature regulator. The water temperature
conditions, damage to engine valve mechanisms can regulator moves to the open position when the jacket
result from engine operation for short intervals. This water coolant temperature has reached the correct
can happen if the engine is started and the engine is operating temperature. The water temperature
EF
stopped many times without being operated in order regulator moves to the open position in order to allow
to warm up completely. the passage of the coolant through the radiator to
dissipate excess heat.
When the engine is operated below normal operating
temperatures, fuel and oil are not completely burned The above procedure is good for normal engine
in the combustion chamber. This fuel and oil causes operating conditions in temperate climates. During
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soft carbon deposits to form on the valve stems. periods of operations in a cold climate with a light
Generally, the deposits do not cause problems and engine load, the coolant must bypass the radiator in
the deposits are burned off during operation at order to help prevent excessive cooling of the engine.
normal engine operating temperatures. Coolant that passes through the radiator must be
minimized in order to maintain the engine operating
When the engine is started and the engine is stopped temperature in cold weather.
many times without being operated in order to warm
up completely, the carbon deposits become thicker. Excessive cooling of the engine can be prevented
This will cause the following problems: by a valve that allows unnecessary coolant flow to
be diverted from the water temperature regulator
• Free operation of the valves is prevented. and back to the bottom of the engine block without
passing through the radiator.
• Valves become stuck.
j I
I
32 SEBU7833-01
Operation Section
Note: Perkins discourages the use of all airflow Group 1 fuels are the preferred Group of Fuels for
restriction devices such as radiator shutters . general use by Perkins . Group 1 fuels maximize
Restriction of the airflow can result in the following : engine life and engine performance. Group 1 fuels
high exhaust temperatures, power loss, excessive are usually less available than Group 2 fuels.
fan usage, and reduclion in fuel economy. Frequently, Group 1 fuels are not available in colder
climates during the winter.
Cab heater lines for very cold weather are also
beneficial. These lines provide more available heat Note: Group 2 fuels must have a maximum wear
from the coolant to the cab. The feed from the engine scar of 650 micrometers (HFRR to ISO 12156-1).
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and the return lines from the cab should be insulated
in order to reduce heat loss to the outside air. Group 2 fuels are considered acceptable for issues
of warranty. This group of fuels may reduce the life
Insulating the Air Inlet and Engine of the engine , the engine's maximum power, and the
engine's fuel efficiency.
Compartment
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When Group 2 diesel fuels are used the following
When temperatures below -18 °C (-0 OF) will be
components provide a means of minimizing problems
frequently encountered, an air cleaner inlet that
in cold weather:
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is located in the engine compartment may be
specified. An air cleaner that is located in the engine
• Glow plugs (if equipped)
compartment may also minimize the entry of snow
into the air cleaner. Also, heat that is rejected by the
• Engine coolant heaters, which may be an OEM
engine helps to warm the intake air.
option
insulating the engine compartment.

E
Additional heat can be retained around the engine by
Fuel heaters, which may be an OEM option
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• Fuel line insulation, which may be an OEM option
i02237463
There are three major differences between Group
Fuel and the Effect from Cold
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1 fuels and Group 2 fuels . Group 1 fuels have the

following different characteristics to Group 2 fuels.
Weather
• A lower cloud point
Note: Only use grades of fuel that are recommended • A lower pour point
ER
by Perkins . Refer to this Operation and Maintenance

A higher rating of kJ (BTU) per unit volume of fuel
Manual, "Fluid Recommendations".
The cloud point is the temperature when a cloud of
The following fuels can be used in this series of
wax crystals begins to form in the fuel. These crystals
engine.
can cause the fuel filters to plug . The pour point is
the temperature when diesel fuel will thicken . The
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• Group 1 diesel fuel becomes more resistant to flow through

fuel pumps and through the fuel lines.
• Group 2
Be aware of these values when diesel fuel is
• Group 3 purchased . Consider Ihe average ambient air
temperature for the engine's application . Engines
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• Special Fuels
that are fueled in one climate may not operate well if
the engines are moved to another climate. Problems
Perkins prefer only Group 1 and Group 2 fuels for use
can result due to changes in temperature.
in this series of engines. Group 3 fuels include Low
Temperature Fuels and Aviation Kerosene Fuels.
Before troubleshooting for low power or for poor
performance in the winter, check the Iype of fuel that
Note: Group 3 fuels reduce the life of the engine . The
is being used.
use of Group 3 fuels is not covered by the Perkins
warranty.
Low temperature fuels may be available for engine
operation at temperatures below 0 °C (32 OF). These
Special fuels include Biofuel.
fuels limit the formation of wax in the fuel at low
temperatures. Wax in the fuel may prevent the flow
of the fuel through the fuel filters .
SEBU7833-01 33
Operation Section
For more information on cold weather operation, refer i01903588

to the Operation and Maintenance Manual , "Cold
Weather Operation and Fuel Related Components in Fuel Related Components in
Cold Weather". Cold Weather
Fuel Tanks
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Condensation can form in partially filled fuel tanks .
Top off the fuel tanks after you operate the engine.
Fuel tanks should contain some provision for draining

water and sediment from the bottom of the tanks.
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Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.
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Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
E
Drain the water and sediment from any fuel storage
tank at the following intervals: weekly, oil changes,
C
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.
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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
ER
system. Refer to the Operation and Maintenance

Manual in the Maintenance Section for more
information on priming the fuel system.
The micron rating and the location of a primary fuel

filter is important in cold weather operation. The
EF
primary fuel filter and the fuel supply line are the most
common components that are affected by cold fuel.
Fuel Heaters
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Note: The OEM may equip the application with fuel

heaters. If this is the case, disconnect an electric type
of fuel heater in warm weather in order to prevent
overheating of the fuel. If the type of fuel heater is a
heat exchanger, the OEM should have included a
bypass for warm weather. Ensure that the bypass is
operational during warm weather in order to prevent
overheating of the fuel.
For more information about fuel heaters (if equipped),

refer to the OEM information.
34 SEBU7833-01
Maintenance Section
Refill Capacities
Maintenance Section Cooling System

To maintain the cooling system, the Total Cooling
System capacity must be known . The approximate
Refill Capacities capacity for the engine cooling system is listed
below. External System capacities will vary among
applications. Refer to the OEM specifications for the
i02198350 External System capacity. This capacity information
will be needed in order to determine the amount
Refill Capacities
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of coolant/antifreeze that is required for the Total
Cooling System .
1104 Engine
Lubrication System
Table 7
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The refill capacities for the engine crankcase 1104 Naturally Aspirated Engine
reflect the approximate capacity of the crankcase
or sump plus standard oil filters. Auxiliary oil filter Compartment or System Liters Quarts
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systems will require additional oil. Refer to the OEM
Engine Only 10.4 11
specifications for the capacity of the auxiliary oil filter.
Refer to the Operation and Maintenance Manual, External cooling system capacity
"Maintenance Section" for more information on (OEM recommendation) (1)
Lubricant Specifications.
1104 Engine
E Total Cooling System ~)
(1) The external cooling system includes a radiator or an

expansion tank with the following components : heat exchanger,
C
aftercooler, and piping . Refer to the OEM specifications . Enter
Table 5 the value for the external system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine
1104 Engine
cooling system plus the capacity for the external cooling
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Compartment or System Liters Quarts system . Enter the total in this row.
Standard Oil Sump for the Engine Table a

6.5 7
Crankcase (1)
1104 Turbocharged Engine
(1) These values are the approximate capacities for the crankcase
oil sump which include the standard factory installed oil filters . Compartment or System Liters Quarts
Engines with auxifiary oil filters will require additional oil. Refer
Engine Only 11.4 12
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to the OEM specifications for the capacily of the auxiliary oil

filter.
External cooling System capacity
(OEM recommendation) (1)
1103 Engine
Total Cooling System (2)
Table 6 (1) The external cooling system includes a radiator or an

expansion tank with the following components: heat exchanger,
1103 Engine
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aftercooler, and piping. Refer to the OEM specifications . Ente r

Compartment or System Liters Quarts the value for the external cooling system capacity in this row.
(2) The Total Cooling System incl udes the capacity for the engine
Standard Oil Sump for the Engine cooling system plus the capacity for the external cooling
6.5 7 system . Enter the total in this row.
Crankcase {ll
(1) These values are the approximate capacities for the crankcase
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oil sump which include the standard factory installed oil niters .
Engines with auxiliary oil filters will require addi tional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.
I"'"
SE BU7833-01 35
Maintenance Section
Refill Capacities
11 03 Engine API Oils

Tabl e 9 The Engine Oil Licensing and Certification System by
11 03 Naturally Aspirated Engine without an oil cooler the American Petroleum Institute (API) is recognized
by Perkins. For detailed information about this
Compartment or System Uters Quarts system, see the latest edition of the "API publication
En gine Only 4.21 4 No. 1509". Engine oils that bear the API symbol are
authorized by API.
External cooling system capacity
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(0 EM recommendation) (11
To tal Cooling System (2)
(1) The external cooling system includes a radiator or an
SS~\fIC(
expansion tank with the following components: heat exchanger.
a ftercooler, and piping. Refer to the OEM specifications. Enter
0..""
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l he value for the external system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine
"t SAE
C Doling system plus the capacity for the external cooling
s yslem . Enter the total in this row. 15W-40
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Tabl e 10
11 03 Naturally Aspirated Engines and Turbocharged

I' Engines with an oil cooler
I'
Compartment or System Liters Quarts
En gine Only
External cooling system capacity
4.43 4.02
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JIIustraUon 1a
Typical API symbol
900546535
C
(0 EM recommendation) (1) Diesel engine oils CC, CD, CD-2, and CE have
not been API authorized classifications since 1
Total Cooling System ~)
January 1996. Table 11 summarizes the status of the
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(1) The external cooling system includes a radiator or an classifications.

e xpansion tank with the following components: heat exchanger,
a ftercooler, and piping . Refer to the OEM specifications. Ente r Table 11
Ihe value for the external system capacity in this row.
II (2) The Total Cooling System includes the capacity for the engine
C Doling system plus the capacity for the external cooling
API Classifications
S ystem . Enter the total in this row. Current Obsolete
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CF-4, CG-4, CH-4 CE

I! i02203046 CF CC. CD
FI uid Recommendations CF-2(1) CD-2{1)
(1) The classifications CO-2 and American Petroleum Institute
CF-2 are for two-cycle diesel engines. Perkins does not sell
EF
engines that utilize CO-2 and API CF-2 oils.
G eneral Lubricant Information

Terminology
Be cause of government regulations regarding the
cert ification of exhaust emissions from the engine, Certain abbreviations follow the nomenclature of
the lubricant recommendations must be followed. "SAE J754". Some classifications follow "SAE J183"
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abbreviations, and some classifications follow the

En gine Manufacturers Association (EMA) "EMA Recommended Guideline on Diesel Engine
Oil". In addition to Perkins definitions, there are other
Oil s definitions that will be of assistance in purchasing
lubricants. Recommended oil viscosities can be found
The "Engine Manufacturers Association in this publication, "Fluid Recommendations/Engine
Re commended Guideline on Diesel Engine Oil" is Oil" topic (Maintenance Section).
rec ognized by Perkins. For detailed information
abo ut this guideline, see the latest edition of EMA
pub lication, "EMA DHD -1" .
II 36
Maintenance Section
Refill Capacities
SEBU7833-01
Engine Oil DHD-1 oils are recommended for use in extended oil
change interval programs that optimize the life of the
Commercial Oils oil. These oil change interval programs are based
on oil analysis . DHD-1 oils are recommended for
The performance of commercial diesel engine conditions that demand a premium oil. Your Perkins
oils is based on American Petroleum Institute dealer or your Perkins distributor has the specific
(API) classifications. These API classifications are guidelines for optimizing oil change intervals.
developed in order to provide commercial lubricants
fo r a broad range of diesel engines that operate at API CH-4 - API CH-4 oils were developed in order to
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various conditions. meet the requirements of the new high performance
diesel engines . Also, the oil was designed to
Only use commercial oils that meet the following meet the requirements of the low emissions diesel
classifications: . engines . API CH-4 oils are also acceptable for use
in older diesel engines and in diesel engines that
use high sulfur diesel fuel. API CH-4 oils may be
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• EMA DHD-1 multigrade oil (preferred oil)
used in Perkins engines that use API CG-4 and API
• API CH-4 multigrade oil (preferred oil) CF-4 oils . API CH-4 oils will generally exceed the
performance of API CG-4 oils in the following criteria:
O
ACEAE3 deposits on pistons , control of oil consumption, wear
of piston rings , valve train wear, viscosity control,
In order to make the correct choice of a commercial and corrosion .
oil , refer to the following explanations:
Three new engine tests were developed for the API
EMA DHD-1 - The Engine Manufacturers
Association (EMA) has developed lubricant
E
recommendations as an alternative to the API oil
CH-4 oil. The first test specifically evaluates deposits
on pistons for engines with the two-piece steel piston .
This test (piston deposit) also measures the control
C
classification system. DHD-1 is a Recommended of oil consumption. A second test is conducted
Guideline that defines a level of oil performance for with moderate oil soot. The second test measures
these types of diesel engines: high speed , four stroke the following criteria : wear of piston rings, wear of
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cycle, heavy-duty, and light duty. DHD-1 oils may cylinder liners , and resistance to corrosion. A third
be used in Perkins engines when the following oils new test measures the following characteristics with
are recommended : API CH-4, API CG-4 , and API high levels of soot in the oil : wear of the valve train ,
CF-4. DHD-1 oils are intended to provide superior resistance of the oil in plugging the oil filter, and
performance in comparison to API CG-4 and API control of sludge.
CF-4.
In addition to the new tests, API CH-4 oils have
ER
DHD-1 oils will meet the needs of high performance tougher limits for viscosity control in applications that
Perkins diesel engines that are operating in many generate high soot. The oils also have improved
applications. The tests and the test limits that are oxidation resistance. API CH-4 oils must pass an
used to define DHD-1 are similar to the new API additional test (piston deposit) for engines that use
CH-4 classification. Therefore, these oils will also aluminum pistons (single piece). Oil performance is
meet the requirements for diesel engines that require also established for engines that operate in areas
EF
low emissions . DHD-1 oils are designed to control the with high sulfur diesel fuel.
harmful effects of soot with improved wear resistance
and improved resistance to plugging of the oil filter. All of these improvements allow the API CH-4
These oils will also provide superior piston deposit oil to achieve optimum oil change intervals . API
control for engines with either two-piece steel pistons CH-4 oils are recommended for use in extended oil
or aluminum pistons. change intervals . API CH-4 oils are recommended
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for conditions that demand a premium oil. Your

All DHD-1 oils must complete a full test program Perkins dealer or your Perkins distributor has specific
with the base stock and with the viscosity grade of guidelines for optimizing oil change intervals.
the finished commercial oil. The use of "API Base
Oil Interchange Guidelines" are not appropriate for Some commercial oils that meet the API
DHD-1 oils. This feature reduces the variation in classifications may require reduced oil change
performance that can occur when base stocks are intervals . To determine the oil change interval , closely
changed in commercial oil formulations. monitor the condition of the oil and perform a wear
metal analysis .
SEBU7833-01 37
Maintenance Section
Refill Capacities
Table 12
NOTICE Percentage of Sulfur in Oil change interval
Failure to follow these oil recommendations can cause the fuel
shortened engine service life due to deposits andlor
excessive wear. Lower than 0.5 Normal
0.5 to 1.0 0.75 of normal
Total Base Number (TBN) and Fuel Sulfur Greater than 1.0 0.50 of normal
Levels for Direct Injection (DI) Diesel
LY
Engines Lubricant Viscosity Recommendations
for Direct Injection (01) Diesel Engines
The Total Base Number (TBN) for an oil depends on
the fuel sulfur level. For direct injection engines that The correct SAE viscosity grade of oil is determined
use distillate fuel, the minimum TBN of the new oil
by the minimum ambient temperature during
must be 10 times the fuel sulfur level. The TBN is
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cold engine start-up, and the maximum ambient
defined by "ASTM 02896". The minimum TBN of the temperature during engine operation.
oil is 5 regardl ess of fuel sulfur level. Illustration 19
demonstrates the TBN .
O
Refer to Table 13 (minimum temperature) in order
to determine the required oil viscosity for starting a
, cold eng ine.
,
, ~1 Refer to Table 13 (maximum temperature) in order
",
,
V
2
E
to select the oil viscosi ty fo r engine operation at the
highest ambient temperature that is anticipated .
C
Generally, use the highest oil viscosity that is
, available to meet the requi rement for the temperature
, at start-up.
,
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Table 13
y x- - - - - - - - - - Engine Oil Viscosity
g00799818 EMA LRG-1 Ambient Temperature

Illustration 19
API CH-4
(Y) TBN by "ASTM 02896" Viscosity Grade Minimum Maximum
(X) Percentage of fuel sulfur by weight
ER
(1) TBN of new oil SAE OW20 -40 °C (-40 OF) 10 °C (50 OF)
(2) Change the oil when the TBN deteriorates to 50 percent o f
the original TBN . SAE OW30 -40 °C (-40 OF) 30 °C (86 OF)
SAE OW40 -40 °C (-40 OF) 40 °C (104 OF)
Use the following guidelines for fuel sulfur levels tha t
exceed 1.5 percent: SAE 5W30 - 30 °C (-22 OF) 30 °C (86 OF)
EF
SAE 5W40 - 30 °C (-22 OF) 40 °C (104 OF)

• Choose an oil with the highest TBN that meets one
of these classifications: EMA OHO-1 and API CH-4. SAE 10W30 -20 °C (-4 OF) 40 °C (104 OF)
SAE 15W40 -10 °C (14 OF) 50 °C (122 OF)
Reduce the oil change interval. Base the oil
change interval on the oil analysis . Ensure that the
oil analysis includes the condition of the oil and Synthetic Base Stock Oils
R
a wear metal analysis.

Synthetic base oils are acceptable for use in
Excessive piston deposits can be produced by an oil these engines if these oils meet the performance
with a high TBN . These deposits can lead to a loss requirements that are specified for the engine .
of control of the oil consumption and to the polishing
of the cylinder bore . Synthetic base oils generally perform better than
conventional oils in the following two areas:
NOTICE
Operating Direct Injection (01) diesel engines with fuel • Synthetic base oils have improved flow at low
su lphur levels over 0.5 percent wil l require shortened temperatures especially in arctic conditions.
oil change intervals in order to help maintain adequate
wear protection . Synthetic base oils have improved oxidation
stability especially at high operating temperatures.
38 SEBU7833-0 1
II Maintenance Section
Refill Capacities
Some synthetic base oils have performance

characteristics that enhance the service life of the NOTICE
oil. Perkins does not recommend the automatic Shortened engine service life could result if second
extending of the oil change intervals for any type of choice oils are used.
oil.
Re-refined Base Stock Oils Aftermarket Oil Additives
Re-refined base stock oils are acceptable for Perkins does not recommend the use of aftermarket
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use in Perkins engines if these oils meet the additives in oil. It is not necessary to use aftermarket
performance requirements that are specified by additives in order to achieve the engine's maximum
Perkins. Re-refined base stock oils can be used service life or rated performance. Fully formulated ,
exclusively in finished oil or in a combination with finished oils consist of base oils and of commercial
new base stock oils. The US military specifications additive packages . These additive packages are
and the specifications of other heavy equipment blended into the base oils at precise percentages in
N
manufacturers also allow the use of re-refined base order to help provide finished oils with performance
stock oils that meet the same criteria . characteristics that meet industry standards.
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The process that is used to make re-refined base There are no industry standard tests that evaluate
stock oil should adequately remove all wear metals the performance or the compatibility of aftermarket
that are in the used oil and all the additives that additives in finished oil. Aftermarket additives may
are in the used oil. The process that is used to not be compatible with the finished oil's additive
make re-refined base stock oil generally involves the package , which could lower the performance of the
E
process of vacuum distillation and hydrotreating the
used oil. Filtering is adequate for the production of
high quality, re-refined base stock oil.
finished oil. The aftermarket additive could fail to
mix with the finished oil. This could produce sludge
In the crankcase . Perkins discourages the use of
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aftermarket additives in finished oils.
Lubricants for Cold Weather To achieve the best performance from a Perkins
engine, conform to the following guidelines:
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When an engine is started and an engine is operated

in ambient temperatures below -20 "C (-4 "F), use • Select the correct oil, or a commercial oil that meets
multigrade oils that are capable of flowing in low the "EMA Recommended Guideline on Diesel
temperatures. Engine Oil" or the recommended API classification.
These oils have lubricant viscosity grades of SAE • See the appropriate "Lubricant Viscosities" table in
ER
OW or SAE 5W. order to find the correct oil viscosity grade for your
engine.
When an engine is started and operated in ambient
temperatures below -30 "C (-22 "F), use a synthetic • At the specified interval , service the engine. Use
base stock multigrade oil with an OW viscosity grade new oil and install a new oil filter.
or with a 5W viscosity grade. Use an oil with a pour
point that is lower than -50 "C (-58 "F).
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• Perform maintenance at the intervals that are

specified in the Operation and Maintenance
The number of acceptable lubricants is limited in Manual, "Maintenance Interval Schedule".
cold weather conditions. Perkins recommends the
following lubricants for use in cold weather conditions:
5·0·5 Oil analysis
First Choice - Use oil with an EMA DHD-1
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Recommended Guideline. Use a CH-4 oil that has Some engines may be equipped with an oil sampling
an API license. The oil should be either SAE OW20 valve. If S·O·S oil analysis is required the oil sampling
SAE OW30, SAE OW40, SAE 5W30, or SAE 5W40 ' valve is used to obtain samples of the engine oil. The
lubricant viscosity grade. S·O·S oil analysis will complement the preventive
maintenance program .
Second Choice - Use an oil that has a CH-4
additive package . Although the oil has not been The S·O·S oil analysis is a diagnostic tool that is used
tested for the requirements of the API license, the oil to determine oil performance and component wear
must be either SAE OW20, SAE OW30, SAE OW40, rates. Contamination can be identified and measured
SAE 5W30 , or SAE 5W40. through the use of the S·O·S oil analysis . The S·O·S
oil analysis includes the following tests:
SEBU7833-01
Maintenance Section
39 l
Refill Capacities
• The Wear Rate Analysis monitors the wear of the High sulfur content of the fuel is not normally found
engine's metals. The amount of wear metal and in Europe, North America or Australasia. This can
type of wear metal that is in the oil is analyzed . The cause engine wear. When only high sulfur fuels
increase in the rate of engine wear metal in the are available, it will be necessary that high alkaline
oil is as important as the quantity of engine wear lubricating oil is used in the engine or that the
metal in the oil. lubricating oil change interval is reduced .
• Tests are conducted in order to detect Distillation

contamination of the oil by water, glycol or fuel.
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This is an indication of the mixture of different
• The Oil Condition Analysis determines the loss of hydrocarbons in the fuel. A high ratio of light weight
the oil's lubricating properties. An infrared analysis hydrocarbons can affect the characteristics of
is used to compare the properties of new oil to the combustion .
properties of the used oil sample. This analysis
allows technicians to determine the amount of Lubricity
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deterioration of the oil during use. This analysis
also allows technicians to verify the performance This is the capability of the fuel to prevent pump wear.
of the oil according to the specification during the
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entire oil change interval. Diesel engines have the ability to burn a wide variety
of fuels. These fuels are divided into four general
groups:
Fuel Specifications
• Group 1 (preferred fuels)
Fuel Recommendations
To get the correct power and performance from
E
• Group 2 (permissible fuels)
C
the engine, use a fuel of the correct quality. The • Group 3 (aviation kerosene fuels)
recommended fuel specification for Perkins engines
is shown below: • Other fuels
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• Cetane number_ _ _ _ _ _ _ _·45 minimum Group 1 (preferred fuels): Specification

• Viscosity_ _ _ _ 2,0 to 4.5 cSt at 40 "C (104 "F) "DERV to EN590"
• Density_ _ _ _ _ _ _ O.835 to 0.855 Kg/liter
°
Note: Only use Arctic fuels when the temperature is
°
below "C (32 "F). Do not use Arctic fuels when the
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• Sulfur_ _ _ _ _ _ _ O.2% of mass, maximum ambient temperature is above "C (32 "F) . To ensure
that the time period between cranking the engine and
• Distillation _ __ _ __ 85% at 350 "C (662 "F) first fire is kept to a minimum, only use fuel of the
correct viscosity and at the correct temperature .
• Lubricity 460 micrometers
maximum wear scar on "ISO 12156 -1 " Gas oil to "BS2869 Class A2"
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Cetane number "ASTM 0975 - 91 Class 2D" This can only be used if
the fuel has the correct specification of lubricity.
This indicates the properties of ignition of the fuel.
Fuel with a low cetane number can be the root "JIS K2204 (1992) Grades 1,2,3 and Special Grade
cause of problems during cold start. This will affect 3" This can only be used if the fuel has the correct
R
combustion . specification of lubricity.

Viscosity Note: If low sulfur or low sulfur aromatic fuels are
used , then fuel additives can be used to increase
This is the resistance to flow of a fluid . If this lubricity.
resistance is outside the limits, the engine and the
engine starting performance in particular can be Group 2 (permissible fuels): Specification
affected.
These fuel specifications are considered acceptable
Sulfur
for issues of warranty. However,these fuels may
reduce the life of the engine, the engine's maximum
power and the engine's fuel efficiency.
II
40 SEBU7833-01
Maintenance Section
Refill Capacities
"ASTM 0975 - 91 Class 10 " The preferred fuels provide maximum engine service
life and performance. The preferred fuels are distillate
"JP7, Mil T38219" fuels. These fuels are commonly called diesel fuel
or gas oil.
"NATO F63"
The permissible fuels are crud e oils or blended fuels.
NOTICE Use of these fuels can resu lt in higher maintenance
These fuels should have a wear scar value of 650 costs and in reduced engine service life.
micrometers maximum *HFRR to ISO 12156 - 1.*
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Diesel fuel s that meet the specifications in Table
14 will help to provide maximum engine service life
Group 3 (aviation kerosene fuels): Specification and performance. In North America, diesel fuel that
is identified as No. 2-D in "ASTM 0975" generally
These fuels need additives to achieve lubricity" of 650 meets the specifications. Table 14 is for diesel fu els '
micrometers wear scar and the reliability of the fuel that are distilled from crude oil. Diesel fuels from
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injection pump will be reduced . The fuel injection other sources could exhibit detrimental properties
pump is not covered by a warranty, even when the that are not defined or controlled by this specification .
additives are included .
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Table 14
"JP5 MIL T5624 (Avcat FSll , NATO F44"
Perkins Specifications for Distillate Diesel Fuel
"JP8 T83133 (Avtur FSll , NATO F34" Specifications Requirements ASTM Test
Aromatics 35% maximum "01319"
"Jet A"
"Jet A1 , NATO F35, XF63"

E Ash
0.02% maximum
(weight)
"0482"
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Carbon Residue 0.35% maximum
Low temperature fuel s "0524"
on 10% Bottoms (weight)
Special fuels for use in cold weather may be available 40 minimum (01
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for engine operation at temperatures below 0 °C Cetane Number engines) "0613"

(32 OF). These fuels limit the formation of wax in the
fuel oil at low temperatures. If wax forms in the fuel The cloud
oil, this could stop the fiow of fuel oil through the filter. point must not
exceed th e
Cloud Point
lowest expected -
Note: These fuels that lack lubricity may cause th e ambient
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following problems: temperature .

(conllnued:
• Low engine power
• Difficult starting in hot conditions or in cold

conditions
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• White smoke
• Deterioration of emissions and misfire at certain

operating conditions
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Biofuet: Specification
Biofuel : A 5% mix of RME to EN14214 in conventional

fuel is permitted.
NOTICE
Water emulsion fuels: These fuels are not permitted
Refer to the following fuet specifications for

North America.
SEBU7833-01
Maintenance Section
41
Refill Capacities
l
(Table 14 eonld)
Copper Strip No.3 maximum NOTICE

"D130" Operating with fuels that do not meet the Perkins rec-
Corrosion
ommendations can cause the following effects: Start-
10% at 282 °C ing difficulty, poor combustion, deposits in the fuel in-
(540 OF)
jectors, reduced service life of the fuel system, de-
maximum
Distillation "D86" posits in the combustion chamber, and reduced ser-
90% at 360 °C vice life of the engine.
(680 OF)
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maximum
"D93" NOTICE
Flash Point legal limit
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
N
6 °C (10 OF) to use distillate fuel.
minimum
Pour Point "D97"
below ambient
temperature In extreme cold ambient conditions, you may use the
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distillate fuels that are specified in Table 15. However,
0.2% maximum "D3605" the fuel that is selected must meet the requirements
Sulfur (1) or that are specified in Table 14. These fuels are
"D1552" intended to be used in operating temperatures that
2 .0 cSt minimum are down to -54 °C (-65 OF).
Kinematic
Viscosity ~)
and 4.5 cSt
maximum at
40 °C (104 OF)
"D445"
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Table 15
Distillate Fuels (1)
C
Water and 0.1 % maximum
"D1796" Specification Grade
Sediment
"MIL-T-5624R" JP-5
"D1744"
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Water 0.1% maximum

"ASTM D1655" Jet-A-1
0.05% maximum
Sediment "D473"
(weight) "MIL-T-83133D" JP-8
Gum and Resins 10 mg per 100 "D381"
( 1) The fuels that are listed in this Table may not meet the
~) mL maximum requirements that are specified in the "Perkins Specifications
for Distillate Diesel Fuel" Table . Consult the supplier for the
0.38 mm
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recommended additives in order to maintain the correct fuel

(0.015 inch) lubricity.
Lubricity (4) "D6079"
maximum at
25 °C (77 OF) These fuels are lighter than the No.2 grades of fuel.
(1 ) Perkins fuel systems and engIne components can operate The cetane number of the fuels in Table 15 must be
on high sulfur fuels . Fuel sulfur levels affect exhaust at least 40. If the viscosity is below 1.4 cSt at 38 °C
emissions. High sulfur fuels also increase the potential (100 OF), use the fuel only in temperatures below
o "C (32 "F). Do not use any fuels with a viscosity
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for corrosion of internal components. Fuel sulfur levels

above 0.5 percent may significantly shorten the oil change
intelVaL For additional information, see this publication , "fluid
of less than 1.2 cSt at 38 °C (100 OF). Fuel cooling
Recommendations/Engine Oil" topic (Maintenance Section). may be required in order to maintain the minimum
(2) The values of the fuel viscosity are the values as the fuel viscosity of 1.4 cSt at the fuel injection pump.
is delivered to the fuel injection pumps. If a fuel with a low
viscosity is used, cooling of the fuel may be required to There are many other diesel fuel specifications that
R
maintain a 1.4 cSt viscosity at the fuel injection pump. Fuels

with a high viscosity might require fuel heaters in order to bring
are published by governments and by technological
down the viscosity to a 20 cSt viscosity. societies. Usually, those specifications do not
(3) Follow the test conditions and procedures for gasoline (motor). review all the requirements that are addressed
(4) The lubricity of a fuel is a concern with low sulfur fuel. To in this specification. To ensure optimum engine
determine the lubricity of the fuel , use either the "ASTM 06078 performance, a complete fuel analysis should be
Scuffing Load Wear Test (SBOCLE)" or the "ASTM 06079 High obtained before engine operation. The fuel analysis
Frequency Reciprocating Rig (HFRR)" test. If the lubricity of a
fuel does not meet the minimum requirements, consult your
should include all of the properties that are listed in
fuel supplier. Do not treat the fuel without consulting the fuel Table 14.
supplier. Some additives are not compatible . These additives
can cause problems in the fuel system .
42 SEBU7833-01
Refill Capacities
Cooling System Specifications DO NOT use the following types of water in cooling
systems: Hard water, softened water that has been
General Coolant Information conditioned with salt, and sea water.
If distilled water or deionized water is not available,

NOTICE
use water with the properties that are listed in Table
Never add coolant to an overheated engine . Engine
16.
damage could result. Allow the engine to cool first.
Tab le 16
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NOTICE Perkins Minimum Acceptable Water Requirements
If the engine is to be stored in , or shipped to an area Property Maximum Limit
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temper- Chloride (CI) 40 mg/L
ature or drained completely to prevent damage. Sulfate (SO.) 100 mg/L
N
Total Hardness 170 mg/L
NOTICE
Frequently check the specific gravity of the coolant for Total Solids 340 mg/L
O
proper freeze protection or for anti-boil protection . Acidity pH of 5.5 to 9.0
Clean the cooling system for the following reasons : For a water analysis, consult one of the following
sources :
Contamination of the cooling system
• Overheating of the engine

E • Local water utility company
• Agricultural agent
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• Foaming of the coolant
• Independent laboratory
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NOTICE
Never operate an engine without water temperature Additives
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the Additives help to protect the metal surfaces of
proper operating temperature . Cooling system prob- the cooling system. A lack of coolant additives or
lems can develop without water temperature regula- insufficient amounts of additives enable the following
tors. conditions to occur:
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• Corrosion
Many engine failures are related to the cooling
system. The following problems are related to cooling
• Formation of mineral deposits
system failures: Overheating , leakage of the water
pump , and plugged radiators or heat exchangers.
• Rust
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These failures can be avoided with correct cooling

• Scale
system maintenance. Cooling system maintenance is
as important as maintenance of the fuel system and
• Foaming of the coolant
the lubrication system. Quality of the coolant is as
important as the quality of the fuel and the lubricating
Many additives are depleted during engine operation.
oil.
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These additives must be repla ced periodically.

Coolant is normally composed of three elements:
Additives must be added at the correct concentration .
Water, additives, and glycol.
Overconcentration of additives can cause the
inhibitors to drop out-of-solution . The deposits can
Water enable the following problems to occur:
Water is used in the cooling system in order to • Formation of gel compounds

transfer heat.
• Reduction of heat transfer
Distilled water or deionized water is
recommended for use in engine coating systems. • Leakage of the water pump seal
SEBU7833-01 43
Maintenance Section
Refill Capacities
• Plugging of radiators, coolers, and small passages Preferred - Perkins Extended Life Coolant (ELC)
Glycol Acceptable - A commercial heavy-duty

coolantiantifreeze that meets "ASTM D4985"
Glycol in the coolant helps to provide proteclion specifications
against the following conditions :
NOTICE
Boiling Do not use a commercial coolantiantifreeze that on-
ly meets the ASTM D3306 specification. This type of
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• Freezing coolantiantifreeze is made for light automotive appli-
cations .
Cavilation of the water pump
Perkins recommends a 1:1 mixture of water
For optimum performance, Perkins recommends a
1:1 mixture of a water/glycol solution . and glycol. This mixture of water and glycol will
N
provide optimum heavy-duty performance as a
Note: Use a mixture that will provide proteclion coolant/antifreeze. This ratio may be increased to 1:2
against the lowes I ambient temperature. water to glycol if exira freezing protection is required .
O
Note: 100 percent pure glycol will freeze at a Note: A commercial heavy-duty coolantiantifreeze
temperature of -23 °C (-9 OF). that meets "ASTM D4985" specifications MAY require
a treatment with an SCA at the initial fill. Read the
Most conventional coolantiantifreezes use ethylene label or the instructions that are provided by the OEM
glycol. Propylene glycol may also be used. In a 1:1
mixture with water, ethylene and propylene glycol
provide similar protection against freezing and E
of the product.
In stationary engine applications and marine engine

C
boiling . See Tables 17 and 18. applications that do not require anti-boil protection
or freeze protection, a mixture of SCA and water
Table 17 is acceptable. Perkins recommends a six percent
to eight percent concentration of SCA in those
EN
Ethylene Glycol cooling systems. Distilled water or deionized water

Freeze Boil is preferred . Water which has the recommended
Concentration properties may be used.
Protection Protection
50 Percent -36 °C (-33 OF) 106 °C (223 OF) Engines that are operating in an ambient temperature
60 Percent - 51 °C (-60 OF) 111 °C (232 OF) above 43°C (109.4 OF) must use SCA and water.
ER
Engines that operate in an ambient temperature

above 43 °C (109.4 OF) and below 0 °C (32 OF) due
NOTICE to seasonal variations consult your Perkins dealer
Do not use propylene glycol in concentrations that ex- or your Perkins distributor for the correct level of
ceed 50 percent glycol because of propylene glycol's protection.
reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
EF
boiling or freezing.
Tab le 18
Propylene Glycol
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Freeze Anti-Boil
Concentration
Protection Protection
50 Percent - 29 °C (-20 OF) 106 'c (223 OF)
To check the concentration of glycol in the coolant,

measure the specific gravity of the coolant.
Coolant Recommendations
The following two coolants are used in Perkins diesel
engines:
44 SEBU7833-01
Refill Capacities
Table 19 ELC Cooling System Maintenance

Coolant Service Life
Correct additions to the Extended Life
Coolant Type Service Life
Coolant
12,000 Service Hours
Perkins ELC or Six Years
NOTICE
Commercial Heavy-Duly Use only Perkins products for pre-mixed or concen-
3000 Service Hours or
Coolant/Antifreeze that Two Years
trated coolants.
meets "ASTM 04985"
LY
Perkins POWERPART 3000 Service Hours or Use only Perkins Extender with Extended Life
SCA Two Years Coolant.
Commercial SCA and 3000 Service Hours or Mixing Extended Life Coolant with other products re,
Waler Two Years duces the Extended Life Coolant service life. Failure to
N
follow the recommendations can reduce cooling sys-
tem components life unless appropriate corrective ac-
Extended Life Coolant (ELC) tion is performed .
O
Perkins provides Extended Life Coolant (ELC) for
use in the following applications : In order to maintain the correct balance between
the antifreeze and the additives, you must maintain
• Heavy-duty spark ignited gas engines the recommended concentration of Extended Life
Coolant (ELC). Lowering the proportion of antifreeze
• Heavy-duty diesel engines
• Automotive applications E lowers the proportion of additive. This will lower the
ability of the coolant to protect the system from pitting ,
from cavitation, from erosion, and from deposits.
C
The anti-corrosion package for ELC is different from
NOTICE
the anti-corrosion package for other coolants. ELC
Do not use a conventional coolant to top-off a cooling
EN
is an ethylene glycol base coolant. However, ELC

system that is filled with Extended Life Coolant (ELC).
contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrile. Perkins ELC
Do not use standard supplemental coolant additive
has been formulated wilh the correct amount of
(SCA). Only use ELC Extender in cooling systems that
these additives in order to provide superior corrosion
are filled with ELC .
protection for all metals in engine cooling systems.
ER
ELC extends the service life of the coolant to 12000 Perkins ELC Extender
service hours or six years . ELC does not require
a frequent addition of a Supplemental Coolant ELC Extender is added to the cooling system halfway
Additive (SCA). An Extender is the only additional through the ELC service life. Treat the cooling system
maintenance that is needed at 6000 service hours or with ELC Extender at 6000 hours or three years. Use
one half of the ELC service life. Table 20 in order to determine the correct amount of
EF
ELC Extender that is required.

ELC is available in a 1:1 premixed cooling solution
with distilled water. The Premixed ELC provides Containers of several sizes are available. Consult
freeze protection to -36 °C (-33 OF) . The Premixed your Perkins dealer or your Perkins distributor for the
ELC is recommended for the initial fill of the cooling part numbers .
system. The Premixed ELC is also recommended for
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topping off the cooling system . Use the formula in Table 20 to determine the correct
amount of ELC Extender for your cooling system .
ELC Concentrate is also available . ELC Concentrate Refer to Operation and Maintenance Manual , "Refill
can be used to lower the freezing point to -51 °C Capacities" in order to determine the capacity of the
(-60 OF) for arctic conditions . cooling system .
Containers of several sizes are available. Consult Table 20

your Perkins dealer or your Perkins distributor for the
Formula For Adding ELC Extender To ELC
part numbers.
v x 0.02 = X
V is the total capacity of the cooling system.
X is the amount of ELC Extender that is required.
SEBU7833-01 45
Maintenance Section
Refill Capacities
Table 21 is an example for using the formula that is 3. Flush the system with clean water in order to
in Table 20. remove any debris.
Table 21 4. Use Perkins cleaner to clean the system . Follow

Example Of The Equation For Adding ELC the instruction on the label.
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)
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6. Fill the cooling system with clean water and
0.18 L operate the engine until the engine is warmed to
9 L (2 .4 US gal) x 0.02 (0.05 US gal) 49° to 66°C (120° to 150°F).
or (6 fi oz)
NOTICE
N
NOTICE Incorrect or incomplete flushing of the cooling system
When using Perkins ELC, do not use standard SCA's can result in damage to copper and other metal com-
or SCA filters. ponents.
O
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 sys tem until all the signs of the
Nole: 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
agents are only required if the system has been
contaminated by the addition of some other type of E
7. Drain the cooling system into a suitable container
and flush the cooling system with clean water. ·1
i
C
coolant or by cooling system damage.
Nole: The cooling system cleaner must be thoroughly
Clean water is the only cleaning agent that is required flushed from the cooling system . Cooling system
EN
when ELC is drained from the cooling system . cleaner that is left in the system will contaminate the
coolant. The cleaner may also corrode the cooling
After the cooling system is drained and after the system .
cooling system is refilled , operate the engine while
the cooling system filler cap is removed . Operate 8. Repeat Steps 6 and 7 until the system is
the engine until the coolant level reaches the normal completely clean .
operating temperature and until the coolant level
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stabilizes . As needed , add the coolant mixture in 9. Fill the cooling system with the Perkins Premixed
order to fil l the system to the specified level. ELC .
Changing to Perkins ELC ELC Cooling System Contamination
To change from heavy-duty coolanUantifreeze to the NOTICE

EF
Perkins ELC, perform the following steps: Mixing ELC with other products reduces the effective-
ness of the ELC and shortens the ELC service life.
NOTICE Use only Perkins Products for premixed or concen-
Care must be taken to ensure that all fluids are trate coolants . Use only Perkins ELC extender with
contained during performance of inspection , main- Perkins ELC . Failure to follow these recommenda-
R
tenance, testing , adjusting and the repair of the tions can result in shortened cooling system compo-
product. Be prepared to collect the fluid with suitable nent life.
containers before opening any compartment or dis-
assembling any component containing fluids. ELC cooling systems can withstand contamination to
a maximum of ten percent of conventional heavy-duty
Dispose of all fluids according to local regulations and coolanUantifreeze or SCA. If the contamination
mandates. exceeds ten percent of the total system capacity,
perform ONE of the following procedures:
1. Drain the coolant into a suitable container.
• Drain the cooling system into a suitable container.
2. Dispose of the coolant according to local Dispose of the coolant according to local
regulations. regulations. Flush the system with clean water. Fill
the system with the Perkins ELC .
46 SEBU7833-01
Maintenance Section
Refill Capacities
• Drain a portion of the cooling system into a suitable Use the equation that is in Table 23 to determine the
container according to local regulations. Then, fill amount of Perkins SCA that is required when the
the cooling system with premixed ELC. This should cooling system is initially filled.
lower the contamination to less than 10 percent.
Table 23
• Maintain the system as a conventional Heavy-Duty Equation For Adding The SCA To The Heavy-Duty
Coolant. Treat the system with an SCA. Change Coolant At The Initial Fill
the coolant at the interval that is recommended for
the conventional Heavy-Duty Coolant. v x 0.045 = X
LY
V is the total volume of the cooling system.
Commercial Heavy-Duty Coolantl X is the amount of SCA that is required.
Antifreeze and SCA
Table 24 is an example for using the equation that
NOTICE is in Table 23 .
N
Commercial Heavy-Duty Coolant which contains
Amine as part of the corrision protection system must Table 24
not be used.
Example Of The Equation For Adding The SCA To
O
The Heavy-Duty Coolant At The Initial Fill
NOTICE Total Volume Multiplication Amount of SCA
Never operate an engine without water temperature of the Cooling Factor that is Required
regulators in the cooling system . Water temperature System (V) (X)
regulators help to maintain the engine coolant at the
E
correct operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.
15 L (4 US gal) x 0.045 0.7 L (24 oz)
C
Adding The SCA to The Heavy-Duty
Coolant For Maintenance
Check the coolant/antifreeze (glycol concentration)
in order to ensure adequate protection against
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Heavy-duty coolant/antifreeze of all types REQUIRE

boiling or freezing. Perkins recommends the use of a periodic additions of an SCA.
refractometer for checking the glycol concentration .
Test the coolant/antifreeze periodically for the
Perkins engine cooling systems should be tested concentration of SCA. For the interval, refer to the
at 500 hour intervals for the concentration of Operation and Maintenance Manual, "Maintenance
Supplemental Coolant Additive (SCA). Interval Schedule" (Maintenance Section). Test the
ER
concentration of SCA.
Additions of SCA are based on the results of the test.
An SCA that is liquid may be needed at 500 hour Additions of SCA are based on the results of the
intervals. test. The size of the cooling system determines the
amount of SCA that is needed .
Refer to Table 22 for part numbers and for quantities
of SCA.
EF
Use the equation that is in Table 25 to determine the

amount of Perkins SCA that is required, if necessary:
Ta ble 22
Perkins Liquid SCA Table 25
Part Number Quantity Equation For Adding The SCA To The Heavy-Duty
Coolant For Maintenance
R
21825755
vx 0.014 = X
V is the total volume of the cooling system.
Adding the SCA to Heavy-Duty Coolant
at the Initial Fill X is the amount of SCA that is required .
Commercial heavy-duty coolant/antifreeze that Table 26 is an example for using the equation that
meets "ASTM 04985" specifications MAY require is in Table 25 .
an addition of SCA at the initial fill. Read the label
or the instructions that are provided by the OEM of
the product.
SEBU7833-01 47
Maintenance Section
Refill Capacities
Table 26
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) x 0.014 0.2 L (7 oz)
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Cleaning the System of Heavy-Duty
Coolant/Antifreeze
Perkins cooling system cleaners are designed
to clean the cooling system of harmful scale
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and corrosion . Perkins cooling system cleaners
dissolve mineral scale, corrosion products , light oil
contamination and sludge .
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• Clean the cooling system after used coolant is
drained or before the cooling system is filled with
new coolant.
• Clean the cooling system whenever the coolant is

contaminated or whenever the coolant is foaming.
E
C
EN
ER
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R
48 SEBU7833-0'
Maintenance Interval Schedule
i02207245 Rad iator - Clean ............ ... ............ ......................... 7;

Maintenance Interval Schedule Every 1000 Service Hours
Engine Valve Lash - Inspect/Adjust ................. .... 6'
Ensure that the Safety Information, Warnings, Every 2000 Service Hours
and Instructions are read and understood
before operation or maintenance procedures are Aftercooler Core - Inspect ..................................... 41
performed. Alternator - Inspect .................. ......... ............. ... .... 51
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Eng ine Mounts - Inspect .. ................ .................... . 6'
Before each consecutive interval is performed , all Starting Motor - Inspect .......................... ............. 7:
of the maintenance requirements from the previous Turbocharger - Inspect ......................... .. ............... 7:
interval must also be performed . . Water Pump - Inspect .......................................... . 7)
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Note: Only engines that are equipped with the Every 2 Years
leak-off fuel injector require servicing every 3000
hours. Coaling System Coolant - Change ...................... 51
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When Required Every 3000 Service Hours
Battery - Replace ............. .... ................................. 51 Fuel Injector - Test/Change ................... . ........ 6,
Battery or Battery Cable - Disconnect ..... ........ ..... 52
Engine - Clean ...................................................... 57 Every 3000 Service Hours or 2 Years
Engine Air Cleaner Element (Dual Element) -
E
Clean/Replace ....... .... ....... ..... .. ........... ................
Engine Air Cleaner Element (Single Element) -
58 Cooling System Coolant (Commercial Heavy-Duty) -
Change ......................................................... 5:
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Inspect/Replace ................................................ 60
Engine Oil Sample - Obtain .................................. 61 Every 4000 Service Hours
Fuel Injector - Test/Change ................................... 64 Aftercooler Core - CleanlTest ............................... 4'
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Fuel System - Prime ............. .... .... ........... ............. 65

Severe Service Application - Check ..................... 72
Every 6000 Service Hours or 3 Years
Daily Cooling System Coolant Extender (ELC) - Add .... 5'
Alternator and Fan Belts - Inspect/Adjust/
Every 12 000 Service Hours or 6 Years
Replace ............ .... ..... .......... ......... ....................... 50
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Cooling System Coolant Level - Check ................ 56 Cooling System Coolant (ELC) - Change ............ 5,
Driven Equipment - Check .................................... 57
Engine Air Cleaner Service Indicator - Inspect ..... 60
Engine Oil Level - Check ......... ............................. 61
Fuel System Primary FilteriWater Separator -
Drain ..................... .. ........ .................... ........ ... ..... 66
EF
Walk-Around Inspection ................................ ........ 74
Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................ 70
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Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 51
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 58
Engine Air Cleaner Element (Single Element) -
Inspect/Replace ................... ...... .... ........... ....... ... 60
Engine Ground - Inspect/Clean ............................ 61
Engine Oil and Filter - Change .................. .......... . 62
Fuel System Primary Filter (Water Separator)
Element - Replace .. ..... .............. .................. ....... 67
Fuel System Secondary Filter - Replace .. ......... ... 68
Hoses and Clamps - Inspect/Replace .................. 71
SEBU7833-01 49
Maintenance Section
Aftercooler Core - CleanlTest
i01853891 Inspect the aftercooler for these items: damaged fins,

corrosion, dirt, grease , insects, leaves, oil, and other
Aftercooler Core - Clean/Test debris. Clean the aftercooler, if necessary.
For air-to-air aftercoolers, use the same methods that

are used for cleaning radiators.
1. Remove the core. Refer to the OEM information
for the correct procedure.
A WARNING
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2. Turn the aftercooler core upside-down in order
to remove debris. Personal injury can result from air pressure.
NOTICE . Personal injury can result without following prop-

Do not use a high concentration of caustic cleaner to er procedure. When using pressure air, wear a pro-
clean the core. A high concentration of caustic cleaner tective face shield and protective clothing.
N
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of Maximum air pressure at the nozzle must be less
cleaner. than 205 kPa (30 psi) for cleaning purposes.
O
3. Back flush the core with a suitable cleaner. Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
4. Steam clean the core in order to remove any of the fan 's air flow. Hold the nozzle approximately
6 mm (.25 inch) away from the fins. Slowly move the
residue. Flush the fins of the aftercooler core.
Remove any other trapped debris.
5. Wash the core with hot, soapy water. Rinse the Eair nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
C
core thoroughly with clean water. Pressurized water may also be used for cleaning .
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
A
EN
WARNING water in order to soften mud . Clean the core from

both sides.
Personal injury can resutt from air pressure.
Use a degreaser and steam for removal of oil and
Personat injury can resutt without following prop- grease. Clean both sides of the core. Wash the core
er procedure. When using pressure air, wear a pro- with detergent and hot water. Thoroughly rinse the
tective face shield and protective clothing. core with clean water.
ER
Maximum air pressure at the nozzle must be less After clean ing , start the engine and accelerate the
than 205 kPa (30 psi) for cleaning purposes. engine to high idle rpm . This will help in the removal
of debris and drying of the core. Stop the engine.
6. Dry the core with compressed air. Direct the air in Use a light bulb behind the core in order to inspect
the reverse direction of the normal flow. the core for cleanliness . Repeat the cleaning , if
EF
necessary.
7. Inspect the core in order to ensure cleanliness.
Pressure test the core. If necessary, repair the Inspect the fins for damage. Bent fins may be opened
core. with a "comb".
Note: If parts of the aftercooler system are repaired

R
8. Install the core. Refer to the OEM information for

the correct procedure . or replaced , a leak test is highly recommended .
Inspect these items for good condition: Welds,

i0 1841503 mounting brackets, air lines, connections, clamps,
and seals. Make repairs, if necessary.
Aftercooler Core - Inspect
Note: Adjust the frequency of cleaning according to

the effects of the operating environment.
I
50 SEBU7833-01
I I' Maintenance Section

Alternator - Inspect
i02176674
Alternator - Inspect
Perkins recommends a scheduled inspection of

the alternator. Inspect the alternator for loose
connections and correct battery charging . Inspect the
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ammeter (if equipped) during engine operation in
order to ensure correct battery performance and/or
correct performance of the electrical system. Make
repairs , as required .
Check the alternator and the battery charger for
N
g01 00393E
correct operation. If the batteries are correctly Illustration 20
charged, the ammeter reading should be very near Typica l example
zero . All batteries should be kept charged. The (1) Burroughs Gauge
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batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold , Fit the gauge (1) at the center of the longest free
the battery will not crank the engine. When the length and check the tension . The correct tension
engine is not run for long periods of time or if the is 535 N (120 Ib). If the tension of the belt is below
engine is run for short periods, the batteries may not 250 N (56 Ib) adjust the belt to 535 N (120 Ib).
E
fully charge. A battery with a low charge will freeze
more easily than a battery wi th a full charge. If twin belts are installed , check and adjust the
tension on both belts .
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i01929797
Alternator and Fan Belts - Adjustment

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Inspect/Adjust/Replace
Inspection
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To maximize the engine performance, inspect the

belts for wear and for cracking . Replace belts that are
worn or damaged.
For applications that require multiple drive belts,

replace the belts in matched sets . Replacing only
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one belt of a matched set will cause the new belt to

carry more load because the older belt is stretched. Illustration 21 g01003939
The additional load on the new belt could cause the
new belt to break. 1. Loosen The alternator pivot bolt (2) and the bolt
(3).
If the belts are too loose, vibration causes
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unnecessary wear on the belts and pulleys. Loose 2. Move the alternator in order to increase or
belts may slip enough to cause overheating . decrease the belt tension . Tighten the alternator
pivot bolt and the link bolt to 22 N'm (16 Ib ft).(1) .
To accurately check the belt tension , a suitable gauge
should be used .
Replacement
Refer to the Disassembly and Assembly Manual for
the installation procedure and the removal procedure
for the belt.
SEBU7833-01 51
Maintenance Section
Battery - Replace
i02150857 8. Connect the cable from the NEGATIVE "-" terminal

on the starting motor to the NEGATIVE "-" battery
Battery - Replace terminal.
i02177936
A WARNING Battery Electrolyte Level -

Batteries give off combustible gases which can Check
LY
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.
When the engine is not run for long periods of time or
Ensure proper ventilation for batteries that are in when the engine is run for short periods, the batteries
an enclosure. Follow the proper procedures in or- may not fully recharge. Ensure a full charge in order
N
der to help prevent electrical arcs and/or sparks to help prevent the battery from freezing. If batteries
near batteries. Do not smoke when batteries are are correctly charged, ammeter reading should be
serviced. very near zero.
O
A WARNING
A WARNING
All lead-acid batteries contain sulfuric acid which
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted. E
can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
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Removing the battery cables or the batteries with 1. Remove the filler caps. Maintain the electrolyte
the cover in place may cause a battery explosion level to the "FULL" mark on the battery.
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resulting in personal injury.

If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
1. Switch the engine to the OFF position. Remove
water that is low in minerals. Do not use artificially
all electrical loads. soften ed wa ter.
2. Turn off any battery chargers. Disconnect any
2. Check the condition of the electrolyte with a
ER
battery chargers. suitable battery tester.

3. The NEGATIVE "-" cable connects the NEGATIVE 3. Keep the batteries clean.
"-" battery terminal to the NEGATIVE "-" terminal
on the starting motor. Disconnect the cable from Clean the battery case with one of the following
the NEGATIVE "-" battery terminal.
cleaning solutions:
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4. The POSITIVE "+" cable connects the POSITIVE

• A mixture of 0.1 kg (0.2 Ib) of baking soda and
"+" battery terminal to the POSITIVE "+" terminal
1 L (1 qt) of clean water
on the starting motor. Disconnect the cable from
the POSITIVE "+" battery terminal.
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
R
Note: Always recycle a battery. Never discard a

battery. Return used batteries to an appropriate Thoroughly rinse the battery case with clean water.
recycling facility.
Use a fine grade of sandpaper to clean the
5. Remove the used battery.
terminals and the cable clamps . Clean the items
until the surfaces are bright or shiny. DO NOT
6. Install the new battery.
remove material excessively. Excessive removal
of material can cause the clamps to not fit
Note: Before the cables are connected , ensure that correctly. Coat the clamps and the terminals with
the engine start switch is OFF.
a suitable silicone lubricant or petroleum jelly.
7. Connect the cable from the starting motor to the
POSITIVE "+" battery terminal.
52 SEBU7833-01
Maintenance Section
Battery or Battery Cable - Disconnect
i02150865
NOTICE
Battery or Battery Cable - Keep all parts clean from contaminants.
Disconnect
Contaminants may cause rapid wear and shortened
component life.
A WARNING Clean the cooling system and flush the cooling
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system before the recommended maintenance
The battery cables or the batteries should not be interval if the following conditions exist:
removed with the battery cover in place. The bat-
tery cover should be removed before any servic- The engine overheats frequently.
ing is attempted.
• Foaming is observed .
N
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion The oil has entered the cooling system and the
resulting in personal injury. coolant is conlaminated .
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• The fuel has entered the cooling system and the
1. Turn the start switch to the OFF position . Turn the
coolant is contaminated .
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
Note: When the cooling system is cleaned, only
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2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
clean water is needed.
Note: Inspect the water pump and the water

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temperature regulator after the cooling system has
12 volt batteries are involved. the negative side of
two batteries must be disconnected. been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
EN
3. Tape the leads in order to help prevent accidental

starting .
Drain
4. Proceed with necessary system repairs . Reverse
the sleps in order to reconnect all of the cables.
A WARNING
ER
i02203590 Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
Cooling System Coolant stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
(Commercial Heavy-Duty) - pressure cap slowly in order to relieve the pres-
Change sure.
EF
1. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in
NOTICE order to relieve any pressure. Remove the cooling
Care must be taken to ensure that fluids are contained system filler cap.
during performance of inspection , maintenance, test-
R
ing, adjusting and repair of the product. Be prepared to

collect the fluid wilh suilable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to Local regulations and

mandates .
SEBU7833-01 53
Maintenance Section
Cooling System Coo [ant (Commercia[ Heavy-Duty) - Change
5. Stop the engine and allow the engine to cool.

u Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain cock or remove
the drain plug on the engine. Open the drain cock
a
or remove the drain plug on the radiator. A[[ow
the water to drain. F[ush the cooling system with
clean water.
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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.
N
g01003928
Ill ustration 22
NOT[CE
2. Open the drain cock or remove the drain plug (1) Do not fill the cooling system faster than 5 L
O
on the engine. Open the drain cock or remove the (1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine damage.
Allow the coolant to drain.
NOT[CE
Dispose of used engine coolant or recycle . Various
methods have been proposed to reclaim used coolant E 2. Fill the cooling system with Commercial
Heavy-Duty Coolant. Add Supplemental Coolant
Additive to the coolant. For the correct amount,
C
refer to the Operation and Maintenance Manua[,
for reuse in engine cooling systems . The full distil[ation
"F[uid Recommendations" topic (Maintenance
procedure is the only method acceptable by Perkins to
Section) for more information on cooling system
reclaim the coolant.
specifications. Do not install the cooling system
EN
filler cap .
For information regarding the disposal and the
recycling of used coolant, consult your Perkins dealer 3. Start and run the engine at [ow idle. Increase the
or your Perkins distributor. engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
Flush the cavities of the engine block. Stop the engine.
ER
1. F[ush the cooling system with clean water in order 4. Check the coolant [evel. Maintain the coo [ant level
to remove any debris. within 13 mm (0.5 inch) below the bottom of the
pipe for filling . Maintain the coolant level in the
2. Close the drain cock or install the drain plug in the expansion bottle (if equipped) at the correct [evel.
engine. Close the drain cock or install the drain
5. Clean the cooling system fil[er cap. Inspect the
EF
plug on the radiator.

gasket that is on the cooling system filler cap. [f
the gasket that is on the cooling system fil[er cap
NOT[CE is damaged , discard the old cooling system filler
Do not fill the cooling system faster than 5 L cap and install a new cooling system filler cap. [f
(1 .3 US gal) per minute to avoid air locks. the gasket that is on the cooling system filler cap
is not damaged, use a suitable pressurizing pump
R
Cooling system air locks may result in engine damage. in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
3. Fill the cooling system with clean water. [nstall the filler cap is stamped on the face of the cooling
cooling system filler cap. system filler cap. [f the cooling system filler cap
does not retain the correct pressure , install a new
4. Start and run the engine at [ow idle until the cooling system filler cap.
temperature reaches 49 to 66 °c (120 to 150 OF).
6. Start the engine . Inspect the cooling system for
leaks and for correct operating temperature.
54 SEBU7833-01
Cooling System Coolant (ELC) - Change
i02203595 1. Stop the engine and allow the engine to cool.

Cooling System Coolant (ELC) order to relieve any pressure. Remove the cooling
- Change system filler cap.
u
NOTICE
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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 flu ids.
N
Dispose of all fluids according to Local regulations and
mandates.
O
NOTICE
Keep all parts clean from contaminants. Typical example
Contaminants may cause rapid wear and shortened 2. Open the drain cock or remove the drain plug (1)
component life.
E on the engine . Open the drain cock or remove the

C
Clean the cooling system and flush the cooling Allow the coolant to drain.
system before the recommended maintenance
interval if the following conditions exist:
NOTICE
EN
Dispose of used engine coolant or recycle. Various

• The engine overheats frequently.
methods have been proposed to reclaim used coolant
for reuse in engine cooling systems . The full distillation
• Foaming is observed.
procedure is the only method acceptable by Perkins to
reclaim the coolant.
• The oil has entered the cooling system and the
coolant is contaminated .
ER
For information regarding the disposal and the

• The fuel has entered the cooling system and the recycling of used coolant, consult your Perkins dealer
coolant is contaminated . or your Perkins distributor.
Note: When the cooling system is cleaned , only Flush

clean water is needed when the ELC is drained and
EF
replaced . 1. Flush the cooling system with clean water in order

to remove any debris.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has 2. Close the drain cock or install the drain plug in the
been drained. This is a good opportunity to repl ace engine . Close the drain cock or install the drain
the water pump , the water temperature regulator and plug on the radiator.
R
the hoses , if necessary.
NOTICE
Drain Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
A WARNING Cooling system air locks may result in engine damage.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
3. Fill the cooling system with clean water. Install the
stop the engine and wait until the cooling system
cooling system filler cap .
pressure cap slowly in order to relieve the pres-
4. Start and run the engine at low idle until the
sure.
temperature reaches 49 to 66 ' C (120 to 150 ' F) .
SEBU7833-01 55
Maintenance Section
Cooling System Coolant - Change
5. Stop the engine and allow the engine to cool. i01929799

order to relieve any pressure. Remove the cooling Cooling System Coolant -
system filler cap . Open the drain cock or remove Change
the drain plug on the engine. Open the drain cock
or remove the drain plug on the radiator. Allow
the water to drain. Flush the cooling system with
clean water.
u
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Fill
1. Close the drain cock or install the drain plug on
the engine. Close the drain cock or install the
N
NOTICE
Do not fill the cooling system faster than 5 L
O
(1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine damage.

2. Fill the cooling system with Extended Life

Coolant (ELC) . Refer to the Operation and
Maintenance Manual, "Fluid Recommendations"
E
Drain plug
NOTICE
C
topic (Maintenance Section) for more information Do not drain the coolant while the engine is still hot and
on cooling system specifications. Do not install the the system is under pressure because dangerous hot
cooling system filler cap. coolant can be discharged.
EN
3. Start and run the engine at low idle. Increase the

engine rpm to high idle. Run the engine at high Note: The radiator may not have been provided by
idle for one minute in order to purge the air from Perkins. The following is a general procedure for
the cavities of the engine block. Stop the engine. changing the coolant. Refer to the OEM information
for the correct procedure.
4. Check the coolant level. Maintain the coolant level
ER
within 13 mm (0.5 inch) below the bottom of the 1. Ensure that the vehicle is on level ground.
pipe for filling. Maintain the coolant level in the
expansion bottle (if equipped) at the correct level. 2. Remove the filler cap of the cooling system.
5. Clean the cooling system filler cap. Inspect the 3. Remove the drain plug (1) from the side of the
gasket that is on the cooling system filler cap. If cylinder block in order to drain the engine. Ensure
the gasket that is on the cooling system filler cap that the drain hole is not restricted.
EF
is damaged, discard the old cooling system filler

cap and install a new cooling system filler cap. If 4. Open the radiator drain tap or remove the drain
the gasket that is on the cooling system filler cap plug at the bottom of the radiator in order to
is not damaged , use a suitable pressurizing pump drain the radiator. If the radiator does not have a
in order to pressure test the cooling system filler radiator drain tap or a drain plug, disconnect the
cap. The correct pressure for the cooling system hose at the bottom of the radiator.
R
filler cap is stamped on the face of the cooling

system filler cap. If the cooling system filler cap 5. Flush the coolant system with clean water.
does not retain the correct pressure, install a new
cooling system filler cap. 6. Install the drain plugs and close the radiator drain
tap. Install the radiator hose if the radiator hose
6. Start the engine. Inspect the cooling system for was previously removed.
leaks and for correct operating temperature.
7. Fill the system with an approved antifreeze
mixture. The maximum flow rate is 1 L
(0 .2200 Imp gal) per minute in order to fill the
system. Install the filler cap.
8. Run the engine and check for coolant leaks.

56 SEBU7833-01
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i02151264
A WARNING
Cooling System Coolant
Pressurized System : Hot coolant can cause seri-
Extender (ELC) - Add ous burns. To open the cooling system filler cap,
The Perkins Extended Life Coolant (ELC) does not sure.
need the frequent addition of Supplemental Coolant
LY
Additives (SCA) that are associated with conventional
coolants. The Extender only needs to be added once . 2. Loosen filler cap slowly in order 10 relieve any
pressure. Remove the filler cap.
Check the cooling system only when the engine is
stopped and cool. 3. Pour the correct coolant mixture into the tank.
N
Refer to the Operation and Maintenance Manual,
1. Loosen the cooling system filler cap slowly in "Refill Capacilies and Recommendations" for
order to relieve pressure . Remove the cooling information on the correct mixture and type of
syslem filler cap. coolant. Refer to the Operation and Maintenance
O
Manual, "Refill Capacities and Recommendations"
2. It may be necessary to drain enough coolant from for the cooling system capacity. Do not fill the
the cooling system in order to add the Extender. coolant recovery tank above "COLD FULL" mark.
E
3. Add Extender according to the requirements for
your eng ine's cooling system capacity. Refer to
this Operation and Maintenance Manual, "Refill
Capacities" in the Maintenance Section for the
C
capacity of the cooling system for your eng ine.
Refer to this Operation and Maintenance Manual,
"Fluid Recommendations" information for the
EN
Perkins ELC Extender.
4. Clean the cooling system filler cap. Inspect the

gasket of the cooling system filler cap. If the gasket
is damaged then replace the cooling system filler
cap . Install the cooling system filler cap.
ER
g00103639
Ill ustration 25
i02 151299
4. Clean filler cap and the receptacle . Reinstall the
Cooling System Coolant Level filler cap and inspect the cooling system for leaks.
- Check
Note: The coolant will expand as the coolant heats
EF
up during normal engine operation . The additional

volume will be forced into the coolant recovery tank
during engine operation . When the engine is stopped
Engines With a Coolant Recovery and cool , the coolant will return to the engine.
Tank
Engines Without a Coolant
R
Note: The cooling system may not have been

provided by Perkins . The procedure that follows Recovery Tank
is for typical cooling systems . Refer to the OEM
information for the correct procedures. Check the coolant level when the engine is stopped
and cool.
Check the coolant level when the engine is stopped
and cool.
1. Observe the coolant level in the coolant recovery

tank. Maintain the coolant level to "COLD FULL"
mark on the coolant recovery tank.
....
SEBU7833-01 57
Maintenance Section
Driven Equipment - Check
Perform any maintenance for the driven equipment

which is recommended by the OEM.
i0 1930350
Engine - Clean
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A WARNING
Personal injury or death can result from high volt-
age.
N
900285520
Hlustration 26 Moisture can create paths of electrical conductiv-
Cooling system filter cap ity.
O
Make sure that the electrical system is OFF. Lock
A WARNING out the starting controls and tag the controls "DO
NOT OPERATE".
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap.
sure. E NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean . Remove debris and fluid
C
spills whenever a significant quantity accumulates on
the engine .
1. Remove the cooling system filler cap slowly in
EN
order to relieve pressure. NOTICE

Failure to protect some engine components from
2. Maintain the coolant level within 13 mm (0 .5 inch) washing may make your engine warranty invalid.
of the bottom of the filler pipe . If the engine is Allow the engine to cool for one hour before washing
equipped with a sight glass, maintain the coolant the engine .
level to the correct level in the sight glass .
ER
3. Clean the cooling system filler cap and check the Periodic cleaning of the engine is recommended .
condition of the filler cap gaskets. Replace the Steam cleaning the engine will remove accumulated
cooling system filler cap if the filler cap gaskets are oil and grease . A clean engine provides the following
damaged . Reinstall the cooling system filler cap. benefits:
4. Inspect the cooling system for leaks . • Easy detection of fluid leaks
EF
• Maximum heat transfer characteristics

i00174798
Driven Equipment - Check • Ease of maintenance
Note: Caution must be used in order to prevent

R
electrical components from being damaged by

Refer to the OEM specifications for more information excessive water when the engine is cleaned .
on the following maintenance recommendations for Pressure washers and steam cleaners should not be
the driven equipment: directed at any electrical connectors or the junction of
cables into the rear of the connectors. Avoid electrical
components such as the alternator and the starter.
• Inspection
Protect the fuel injection pump from fluids in order
Adjustment to wash the engine .
• Lubrication
• Other maintenance recommendations

58 SEBU7833-01
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
i0 1915869 Dual Element Air Cleaners

Engine Air Cleaner Element The dual element air cleaner contains a primary air
(Dual Element) - Clean/Replace cleaner element and a secondary air cleaner element.
The primary air cleaner element can be used up
to six times if the element is properly cleaned and
properly inspected. The primary air cleaner element
should be replaced at least one time per year. This
NOTICE replacement should be performed regardless of th e
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Never run the engine without an air cleaner element number of cleanings.
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with The secondary air cleaner element is not servicea ble
damaged pleats, gaskets or seals . Dirt enterin.9 the or washable. Refer to the OEM information for
engine causes premature wear and damage to engine instructions in order to replace the secondary air
components. Air cleaner elements help to prevent air- cleaner element. When the engine is operating in
N
borne debris from entering the air inlet. environments that are dusty or dirty, air cleaner
elements may require more frequent replacement.
NOTICE
O
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine . 4
Servicing the Air Cleaner Elements

Note: The air filter system may not have been
E
C
provided by Perkins. The procedure that follows
is for a typical air filter system . Refer to the OEM
information for the correct procedure.
EN
If the air cleaner element becomes plugged, the air

can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal Illustration 27
g00736431
engine wear. Refer to the OEM information for the
(1) Cover
correct air cleaner elements for your application . (2) Primary air cleaner element
(3) Secondary air cleaner element
ER
• Check the precleaner (if equipped) and the dust (4) Air inl et
bowl daily for accumulation of dirt and debris.
Remove any dirt and debris, as needed . 1. Remove the cover. Remove the primary air
cleaner element.
• Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner 2. The secondary air cleaner element should be
element. removed and discarded for every three cleanings
EF
of the primary air cleaner element.

• The air cleaner element should be replaced at least
one time per year. This replacement should be Note: Refer to "Cleaning the Primary Air Cleaner
performed regardless of the number of cleanings. Elements".
R
Replace the dirty air cleaner elements with clean air 3. Cover the air inlet with tape in order to keep dirt
cleaner elements. Before installation, the air cleaner out.
elements should be thoroughly checked for tears
and/or holes in the filter material. Inspect the gasket 4. Clean the inside of the air cleaner cover and body
or the seal of the air cleaner element for damage . with a clean, dry cloth .
Maintain a supply of suitable air cleaner elements
for replacement purposes . 5. Remove the tape for the air inlet. Install the
secondary air cleaner element. Install a primary
air cleaner element that is new or cleaned .
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.

SEBU7833-01 59
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Cleaning the Primary Air Cleaner

Elements
NOTICE
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to re-
LY
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
N
g00281692
exceed 207 kPa (30 psi). Direct the air flow up the Illustration 28
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage Note: When the primary air cleaner elements are
O
to the pleats. cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
Do not use air filters with damaged pleats, gaskets, or (outside).
seals. Dirt entering the engine will cause damage to
engine components. Aim the hose so that the air flows inside the element
Refer to the OEM information in order to determine

the number of times that the primary filter element can E along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
C
could be forced further into the pleats.
be cleaned. When the primary air cleaner element is
cleaned , check for rips or tears in the filter material. Note: Refer to "Inspecting the Primary Air Cleaner
The primary air cleaner element should be replaced Elements".
EN
at least one time per year. This replacement should

be performed regardless of the number of cleanings .
Vacuum Cleaning
NOTICE Vacuum cleaning is a good method for cleaning
Do not clean the air cleaner elements by bumping or primary air cleaner elements which require daily
tapping. This could damage the seals. Do not use el- cleaning because of a dry, dusty environment.
ER
ements with damaged pleats, gaskets or seals. Dam- Cleaning with pressurized air is recommended prior
aged elements will allow dirt to pass through . Engine to vacu um cleaning . Vacuum cleaning will not remove
damage could result. deposits of carbon and oil.
Visually inspect the primary air cleaner elements Note: Refer to "Inspecting the Primary Air Cleaner
before cleaning . Inspect the air cleaner elements for Elements".
EF
damage to the seal , the gaskets, and the outer cover.

Discard any damaged air cleaner elements. Inspecting the Primary Air Cleaner
Elements
There are two common methods that are used to
clean primary air cleaner elements :
R
• Pressurized air
• Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered , dry air with a
maximum pressure of 207 kPa (30 psi).
60 SEBU7833-0
Engine Air Cleaner Element (Single Element) - Inspect/Replace
Inspect the clean , dry primary air cleaner element. Some engines are equipped with a differential gaug,
Use a 60 watt blue light in a dark room or in a similar for inlet air pressure . The differential gauge for inlet
facility. Place the blue light in the primary air cleaner air pressure displays the difference in the pressure
element. Rotate the primary air cleaner element. that is measured before the air cleaner element and
Inspect the primary air cleaner element for tears the pressure that is measured after the air cleaner
andlor holes. Inspect the primary air cleaner element element. As the air cleaner element becomes dirty,
for light that may show through the filter material. If it the pressure differential rises . If your engine is
is necessary in order to confirm the result, compare equipped with a different type of service indicator,
the primary air cleaner element to a new primary air follow the OEM recommendations in order to servicE
LY
cleaner element that has the same part number. the air cleaner service indicator.
Do not use a primary air cleaner element that has The service indicator may be mounted on the air
any tears andlor holes in the filter material. Do not cleaner element or in a remote location.
use a primary air cleaner element with damaged
pleats, gaskets or seals . Discard damaged primary
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air cleaner elements.
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i02152042
30
Engine Air Cleaner 25-
20-
-
-
Element (Single Element) - 15
Inspect/Replace
E
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Refer to Operation and Maintenance Manual, "Engine
Air Cleaner Service Indicator-Inspect". Illustration 30
9001 0377
EN
Typical service indicator

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

i01909507
The yellow core should latch approximately at the
Engine Air Cleaner Service greatest vacuum that is attained .
Indicator - Inspect If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
Some engines may be equipped with a different indicator may be restricted .
service indicator.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
SEBU7833-01 61
Maintenance Section
Engine Ground - Inspect/Clean
101941505
Engine Ground - Inspect/Clean
Inspect the wiring harness for good connections.
Perkins use the starter motor in order to ground the Illustration 3 1

g00998024
LY
engine. Check the connection on the starter motor at
(Y) "ADD" mark. (X) "FULL" mark .
every oil change. Ground wires and straps should be
combined at engine grounds. All grounds should be
tight and free of corrosion. NOTICE
Perform this maintenance with the engine stopped.
• Clean the grounding stud on the starter motor and
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the terminals with a clean cloth.
Note: Ensure that the engine is either level or that
the engine is in the normal operating position in order
• If the connections are corroded, clean the
to obtain a true level indication.
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connections with a solution of baking soda and
water.
Note: After the engine has been switched OFF, allow
the engine oil to drain to the oil pan before checking
• Keep the grounding stud and the strap clean and
the oil level.
coated with suitable grease or petroleum jelly.
i02177938
E
1. Maintain the oil level between the "ADD" mark (Y)
and the "FULL" mark (X) on the engine oil dipstick.
Do not fill the crankcase above the "FULL" mark
C
Engine Mounts - Inspect (X).
EN
NOTICE
Note: The engine mounts may not have been Operating your engine when the oil level is above the
supplied for this installation by Perkins. Refer to the "FULL" mark could cause your crankshaft to dip into
OEM information for further information on the engine the oil. The air bubbles created from the crankshaft
mounts and the correct bolt torque. dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power.
ER
Inspect the engine mounts for deterioration and for

correct bolt torque. Engine vibration can be caused 2. Remove the oil filler cap and add oil , if necessary.
by the following conditions: Clean the oil filler cap. Install the oil filler cap.
• Incorrect mounting of the engine

i02202699
• Deterioration of the engine mounts
Engine Oil Sample - Obtain
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Any engine mount that shows deterioration should

be replaced. Refer to the OEM information for the
recommended torques .
The condition of the engine lubricating oil may be
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i0 1907673 checked at regular intervals as part of a preventive

maintenance program. Perkins include an oil
Engine Oil Level - Check sampling valve as an option. The oil sampling valve
(if equipped) is included in order to regularly sample
the engine lubricating oil. The oil sampling valve is
positioned on the oil filter head or the oil sampling
A WARNING valve is positioned on the cylinder block.
Hot oil and hot components can cause personal Perkins recommends using a sampling valve in order
injury. Do not allow hot oil or hot components to to obtain oil samples. The quality and the consistency
contact the skin. of the samples are better when a sampling valve is
used . The location of the sampling valve allows oil
that is flowing under pressure to be obtained during
normal engine operation.
62 SEBU7833-01
Maintenance Section
Engine Oil and Filter - Change
Obtain the Sample and the Analysis Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
A WARNING with the draining cold oil. Drain the crankcase with
the engine stopped . Drain the crankcase with the
Hot oil and hot components can cause personal oil warm. This draining method allows the waste
injury. Do not allow hot oil or hot components to particles that are suspended in the oil to be drained
contact the skin. properly.
LY
In order to help obtain the most accurate analysis, Failure to follow this recommended procedure will
record the following information before an oil sample cause the waste particles to be recirculated through
is taken: the engine lubrication system with the new oil.
• The date of the sample Drain the Engine Oil
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• Engine model
• Engine number
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• Service hours on the engine
• The number of hours that have accumulated since

the last oil change
E
• The amount of oil that has been added since the
last oil change
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Ensure that the container for the sample is clean and
dry. Also ensure that the container for the sample is
EN
clearly labelled . 901 003623

Illustration 32
Oil drain plug
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil After the engine has been run at the normal operating
sample. temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
ER
To avoid contamination of the oil samples , the tools

and the supplies that are used for obtaining oil If the engine is equipped with a drain valve, turn the
samples must be clean. drain valve knob counterclockwise in order to drain
the oil. After the oil has drained , turn the drain valve
The sample can be checked for the following : the knob clockwise in order to close the drain valve.
quality of the oil, the existence of any coolant in the
oil , the existence of any ferrous metal particles in
EF
• If the engine is not equipped with a drain valve ,

the oil , and the existence of any nonferrous metal remove the oil drain plug (1) in order to allow the
particles in the oil. oil to drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from both
i0 1929323 ends of the oil pan.

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After the oil has drained , the oil drain plugs should
be cleaned and installed. If necessary, renew the 0
ring seal on the drain plug .
Some types of oil pans have oil drain plugs that are
A WARNING on both sides of the oil pan, because of the shape of
the pan. This type of oil pan requires the engine oil to
Hot oil and hot components can cause personal
be drained from both plugs .
injury. Do not allow hot oil or hot components to
contact the skin.
l
SEBU7833-01 63
Maintenance Section
Replace the Spin-on Oil Filter

NOTICE
NOTICE Do not fill the oil filters with oil before installing them.
Perkins oil filters are manufactured to Perkins speci- This oil would not be filtered and could be contaminat-
fications. Use of an oil filter that is not recommended ed. Contaminated oil can cause accelerated wear to
by Perkins could result in severe damage to the en- engine components .
gine bearings, crankshaft, etc., as a result of the larger
waste particles from unfiltered oil entering the engine 5. Install the oil filter. Tighten the oil filter by hand
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lubricating system. Only use oil filters recommended according to the instructions that are shown on
by Perkins. the oil filter. Do not overtighten the oil filter.
1. Remove the oil filter with a suitable tool. Replace the Element for the Oil
Filter
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Note: The following actions can be carried out as
part of the preventive maintenance program.
2. Cut the oil filter open with a suitable tool. Break
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apart the pleats and inspect the oil filter for metal
debris. An excessive amount of metal debris in
the oil filter may indicate early wear or a pending
failure.
Use a magnet to differentiate between the ferrous

metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate E
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wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the

EN
aluminum parts, brass parts or bronze parts of Illustration 34

901003662
the engine. Parts that may be affected include
(1) Drain plug
the following items: main bearings , rod bearings, (2) Square hole
turbocharger bearings, and cylinder heads. (3) Filter bowl
Due to normal wear and friction, it is not 1. Place a suitable container under the oil filter.
ER
uncommon to find small amounts of debris in the Remove the drain plug (1) and the seal, from the
oil filter. oil filter.
2. Locate a suitable wrench into the square hole (2)

in order to remove the filter bowl (3).
3. Remove the filter bowl (3) and remove the element

EF
from the filter bowl. Clean the filter bowl.
6 ----.....!...f--E~
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5 _ _ _.......-':::::.
IllUstration 33 901003628
(2) Filter head

(3) 0 ring seal
3. Clean the sealing surface of the oil filter head (2). -----..'(
Ensure that the union (not shown) in the oil filter
head is secure. Illustration 35 901003675
(4) 0 ring seal

4. Apply clean engine oil to the 0 ring seal (3) on (5) Element
the oil filter. (6 ) Filter head
64 SEBU7833-0
Engine Valve Lash - InspecVAdjust
4 . Install a new 0 ring (4) onto the filter bowl and i021711(
lubricate the 0 ring with clean engine oil. Install
the filter element (5) into the filter bowl.
Engine Valve Lash -
Inspect/Adjust
5. Install the filter bowl into the oil filter head (6) .
Tighten the filter bowl to the following torque
25 N'm (18 Ib It).
This maintenance is re commended by Perkins as
6. Install a new seal onto the drain plug (1) and part of a lubrication and preventive maintenance
LY
install the drain plug into the oil filter. nghten the schedule in order to help provide maximum engine
drain plug to the followi ng torque 12 N'm (8 Ib It). life.
Note: Some engines may have a horizontally
NOTICE
mounted oil filter. This oil filter has a drain plug that is
Only qualified service personel should perform thi~
located in the oil filter head.
maintenance. Refer to the Service Manual or your au·
N
thorized Perkins dealer or your Perkins distributor fOI
Fill the Engine Crankcase the complete valve lash adjustment procedure.
O
1. Remove the oil filler cap. Refer to the Operation Operation of Perkins engines with incorrect valve lash
and Maintenance Manual for more information on can reduce engine efficiency, and also reduce engine
lubrica nt specifications. Fill the crankcase with the component life.
proper amount of oil. Refer to the Operation and
Maintenance Manual for more information on refill
capaci ties.
E A WARNING
Ensure that the engine can not be started while
C
NOTICE
If equ ipped with an auxiliary oil filter system or a re- this maintenance is being performed. To help pre-
mote oil filter system, follow the OEM or filter manu- vent possible injury, do not use the starting motor
facturer's recommendations. Under filling or overfilling to turn the flywheel.
EN
the crankcase with oil ca n cause engine damage.

Hot engine components can cause burns . Allow
additional time for the engine to cool before mea-
NOTICE suring/adjusting valve lash clearance.
To prevent cran kshalt bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before Ensure that the engine is stopped before measuring
ER
starting the engine . Do not crank the engine for more the valve lash . The engine valve lash can be
than 30 seconds. inspected and adjusted when the temperature of the
engine is hot or cold .
2. Start the engine and run the engine at "LOW
IDLE" for two minutes. Perform this procedure in Refer to Systems OperationlTesting and Adjusting ,
order to ensure that the lubrication system has "Engine Valve Lash - InspecVAdjust" for more
EF
oil and that the oil filters are filled. Inspect the oil information.
filter for oil leaks.
i021 98352
3. Stop the engine and allow the oil to drain back to
the sump for a minimum of ten minutes. Fuel Injector - Test/Change
R
A WARNING
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Illu stration 36 900998024
(Y ) "ADD " mark . (X) "FULL" mark.
4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the "ADD"
and "FULL" ma rks on the engine oil dipstick.
SEBU7833-01 65
Maintenance Section
Fuel System - Prime
The engine misfires or the engine runs erratically.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly • High fuel consumption
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- • Black exhaust smoke
nected fuel system component.
• The engine knocks or there is vibration in the
engine.
NOTICE
LY
If a fuel injector is suspected of operating outside of • Excessive engine temperature
normal parameters it should be removed by a qualified
technician. The suspect fuel injector should be taken Removal and Installation of the
to an authorised agent for inspection .
Fuel Injectors
N
The fuel injector (1) in illustration 37 has no fuel
return. The fuel injector (2) has a fuel return. A WARNING
O
Work carefully around an engine that is running.
Engine parts that are hot, or parts that are moving,
can cause personal injury.
E A WARNING
Make sure that you wear eye protection at all
C
times during testing. When fuel injection nozzles
are tested, test fluids travel through the orifices
of the nozzle tip with high pressure. Under this
amount of pressure, the test fluid can pierce the
EN
skin and cause serious injury to the operator.

Always keep the tip of the fuel injection nozzle
pointed away from the operator and into the fuel
collector and extension.
ER
NOTICE
If your skin comes into contact with high pressure fuel ,
obtain medical assistence immediately.
~ I
~ I
Operate the engine at a fast idle speed in order to
identify the faulty fuel injector. Individually loosen and
EF
tighten the union nut for the high pressure pipe to

each fuel injector. Do not loosen the union nut more
9011 10422
than half a turn. There will be little effect on the engine
Illustration 37 speed when the union nut to the faulty fuel injection
Typical fuel Injectors nozzle is loosened . Refer to the Disassembly and
Assembly Manual for more information. Consult your
R
The fuel injector (1) will need to be removed and the authorized Perkins dealer or your Perkins distributor
injector will need to be checked for performance . for assistance .
The fuel injectors should not be cleaned as cleaning

i01929324
with incorrect tools can damage the nozzle. The fuel
injectors should be renewed only if a fault with the Fuel System - Prime
fuel injectors occurs. Some of the problems that may
indicate that new fuel injectors are needed are listed
below:
If air enters the fuel system , the air must be purged
• The engine will not start or the engine is difficult from the fuel system before the engine can be
to start. started. Air can enter the fuel system when the
following events occur:
• Not enough power
66 SEBU7833-01
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
• The fuel tank is empty or the fuel tank has been 7. The engine is now ready to start. Operate the
partially drained. engine at low idle for a minimum of five minutes
immediately alter air has been removed from the
The low pressure fuel lines are disconnected. fuel system .
A leak exists in the low pressure fuel system. Note: Running the engine for this period of time will
help ensure that the pump is completely free of air.
The fuel filter is replaced .
LY
• A new injection pump is installed . i02211066
Use the following procedure in order to remove air

Fuel System Primary
from the fuel system: FilterlWater Separator - Drain
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1. Remove the cover for the fuel injectors . Refer to
the Disassembly and Assembly Manual.
2. Turn the key switch to the RUN position . Leave the A WARNING
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key switch in the RUN position for three minutes .
Fuel teaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
3. Turn the key switch to the OFF position . vent possible injury, turn the start switch off when
changing fuel filters or water separator elements .
E Clean up fuet spills immediately.

C
NOTICE
The water separator is not a filter. The water separa-
tor separates water from the fuel. The engine should
never be allowed to run with the water separator more
EN
than half full. Engine damage may result.
NOTICE
The water separator is under suction during normal
engine operation . Ensure that the drain valve is tight-
ER
ened securely to help prevent air from entering the fuel

g01003929
Illustration 38 system .
Injector nuts
Note: Damage to the fuel injection pump, to the

battery, and to the starter motor can occur if the
starter motor is used excessively to purge the air
EF
from the fuel system .
4. Loosen the flare nuts (1) for the high pressure fuel
lines on all of the fuel injectors .
R
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again .
5. Observe the connection at the flare nut. Operate

the starting motor and crank the engine until the
fuel is free of air.
6. Tighten the flare nuts (1) to a torque of 30 N'm

(22 Ib It).
SEBU7833-01 67
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
i02206563
Fuel System Primary Filter

(Water Separator) Element -
Replace
LY
A WARNING
. Fuel leaked or spilled onto hot surfaces or elec-
2 trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
N
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
3
O
6 NOTICE
Do not allow dirt to enter the fuel system . Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
5 ---fhFf'~-
4
E
C
901 118416
Illustration 39
EN
(1) Screw
(2) Element
(3) Glass bowl
(4) Sensor connection
(5) Drain
(6) Bottom cover
ER
1. Place a suitable container below the water

separator. 2
2. Open the drain (5). Allow the fluid to drain into the
container.
3
3. When clean fuel drains from the water separator
EF
close the drain (5). Tighten the drain by hand 6

pressure only. Dispose of the drained fluid
correctly.
4
5 _--fl~~-
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901118416
Illustration 40
(1) Screw
(2) Element
(3) Glass bowl
(4) Sensor connection
(5) Drain
(6) Bottom cover
1. Turn the fuel supply valve (if equipped) to the OFF

position.
68 SEBU7833-01
Fuel System Secondary Filter - Replace
2. Place a suitable container under the water Element filter

separator. Clean the outside of the water
separator. Turn the valves for the fuel lines (if equipped) to the
OFF position before performing this maintenance.
3. Open the drain (5). Allow the fluid to drain into the Place a tray under the fue l filter in order to catch
container. any fuel that might spill. Clean up any spilled fuel
immediately.
4. Tighten the drain (5) by hand pressure only.
LY
5. Hold the element (2) and remove the screw (1).
Remove the element and the glass bowl (3) from
the base. Discard the old element.
6. Clean the glass bowl (4). Clean the bottom cover
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(6).
7. Install the new 0 ring seal. Install the bottom

cover onto the new element. Install the assembly 2 - -I++-."tt>I-H-I
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onto the base .
o o
8. Install the screw (1) and tighten the screw to a
torque of 8 N'm (6 Ib tt).
9. Remove the container and dispose of the fuel

safely.
C
E Ii
10. Open the fuel supply valve.
11. Prime the fuel system. Refer to the Operation and g01010637
EN
Illustration 41
Maintenance Manual, "Fuel System - Prime" for
more information. (1) Drain
(2) Filler bowl
i02223550 1. Close the valves for the fuel lines (if equ ipped).
Fuel System Secondary Filter· 2. Clean the outside of the fue l filter assembly. Open
ER
Replace the fuel drain (1) and drain the fuel into a suitable
container.
A WARNING
EF
Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
R
NOTICE
Do not allow dirt to enter the fuel system . Thoroughly
clean the area around a fue l system component thai
will be disconnected. Fit a suitable cover over discon-
nected fu el system component.
SEBU7833-0 1 69
Maintenance Section
Fuel System Secondary Filter - Replace
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N
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Illustration 42 9010 10595
(3) 0 ring sea l

(4) Elemen l
(5) Filler head
E
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3. Remove the filter bowl (2) from the filter head (5).
Press on the element (4). Rotate the element
lIIustralion 43 90 1121396
counterclockwise in order to release the element
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for the filter bowl and remove the element from the (1 ) S pin-on fil ter
bowl. Discard the used element. (2) Drain
4. Remove the 0 ring (3) from the filter bowl and 1. Clean the outside of the fuel filter assembly. Open
clean the filter bowl. Check that the threads of the the fuel drain (3) and drain the fuel into a suitable
filter bowl are not damaged. container.
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5. Install a new 0 ring seal (3) to the filter bowl (2) . 2. Use a suitable tool in order to remove the spin-on
filter (2) from the filter head (1).
6. Locate a new filter element (4) into the filter bowl.
Press on the element and rotate the element 3. Ensure that the fuel drain (3) on the new spin-on
clockwise in order to lock the element into the filter is closed .
filter bowl.
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7. Install the filter bowl (4) into the top of the filter
head (5) .
8. Tighten the filter bowl by hand until the filter bowl

contacts the filter head. Rotate the filter bowl
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through 90 degrees.
Note: Do not use a tool to tighten the filter bowl.
9. Open the valves for the fuel lines (if equipped).
Spin-on filter
Turn the valves for the fuel lines (if equipped) to the
OFF position before performing this maintenance.
Place a tray under the fuel filter in order to catch
any fuel that might spill. Clean up any spilled fuel
immediately.
70
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SEBU7833-01
Maintenance Section
Fuel Tank Water and Sediment - Drain
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
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~---4
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
Drain the Water and the Sediment
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Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks .
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Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
g01 121723
Illu stration 44
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4. Lubricate the sealing ring (4) with clean fuel oil.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
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5. Install the spin-on filter (2) into the top of the filter fuel tank has been filled. Allow five to ten minutes
head (1). before performing this procedure.
6. Tighten the spin-on filter by hand until the sealing Fill the fuel tank after operating the engine in
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ring contacts the filter head . Rotate the spin-on order to drive out moist air. This will help prevent
filter through 90 degrees. condensation. Do not fill the tank to the top . The
fuel expands as the fuel gets warm . The tank may
7. Prime the fuel system . Refer to Operation and overfiow.
Maintenance Manual, "Fuel System - Prime".
Some fuel tanks use supply pipes that allow water
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and sediment to settle below the end of the fuel

i0 1938468
supply pipe. Some fuel tanks use supply lines that
Fuel Tank Water and Sediment take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
- Drain maintenance of the fuel system filter is important.
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Fuel Storage Tanks

NOTICE Drain the water and the sediment from the fuel
Care must be taken to ensure that fiuids are contained storage tank during the following conditions:
during performance of inspection , maintenance, test-
ing , adjusting, and repair of the product. Be prepared • Weekly
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to collect the fiuid with suitable containers before

opening any compartment or disassembling any com- • Oil change
ponent containing fiuids.
Refill of the tank
Dispose of all fluids according to local regulations and
mandates. This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank.
SEBU7833-01 71
Maintenance Section
Hoses and Clamps - InspecUReplace
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 • Type of hose
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel. Type of fitting material
When possible, water separators should be used.
Anticipated expansion and contraction of the hose
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i02169460
Anticipated expansion and contraction of the
Hoses and Clamps - fittings
Inspect/Replace Replace the Hoses and the Clamps
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Refer to the OEM information for further information
on removing and replacing fuel hoses (if equipped).
Inspect all hoses for leaks that are caused by the
following conditions:
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The coolant system and the hoses for the coolant
system are not usually supplied by Perkins. The
• Cracking
following text describes a typical method of replacing
coolant hoses. Refer to the OEM information for
• Softness
further information on the coolant system and the
• Loose clamps
Replace hoses that are cracked or soft. Tighten any E

hoses for the coolant system .
A WARNING
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loose clamps.
Pressurized System : Hot coolant can cause seri-
NOTICE ous burns. To open the cooling system filler cap,
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Do not bend or strike high pressure lines. Do not in- stop the engine and wait until the cooling system
stall bent or damaged lines, tubes or hoses . Repair components are cool. Loosen the cooling system
any loose or damaged fuel and oil lines , tubes and pressure cap slowly in order to relieve the pres-
hoses. Leaks can cause fires. Inspect all lines , tubes sure.
and hoses carefully. Tighten all connections to the rec-
ommended torque. 1. Stop the engine . Allow the engine to cool.
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Check for the following conditions: 2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
End fittings that are damaged or leaking system filler cap.
• Outer covering that is chafed or cut Note: Drain the coolant into a suitable, clean
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container. The coolant can be reused .

• Exposed wire that is used for reinforcement
3. Drain the coolant from the cooling system to a
• Outer covering that is ballooning locally level that is below the hose that is being replaced.
• Flexible part of the hose that is kinked or crushed 4. Remove the hose clamps .
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• Armoring that is embedded in the outer covering 5. Disconnect the old hose .
A constant torque hose clamp can be used in place 6. Replace the old hose with a new hose.
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard 7. Install the hose clamps with a torque wrench.
clamp .
Note: For the correct coolant, see this Operation and
Due to extreme temperature changes, the hose will Maintenance Manual , "Fluid Recommendations".
harden. Hardening of the hoses will cause hose
clamps to loosen . This can result in leaks . A constant 8. Refill the cooling system. Refer to the OEM
torque hose clamp will help to prevent loose hose information for further information on refilling the
clamps. cooling system .
72 SEBU7833-01
Radiator - Clean
9. Clean the cooling system filler cap . Inspect the After cleaning, start the engine and accelerate the
cooling system filler cap's seals. Replace the engine to high idle rpm. This will help in the removal
cooling system filler cap if the seals are damaged. of debris and the drying of the core. Stop the engine.
Install the cooling system filler cap. Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning , if
10. Start the engine. Inspect the cooling system for necessary.
leaks.
Inspect the fins for damage. Bent fins may be opened
with a "comb". Inspect these items for good condition:
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i01907732
Welds, mounting brackets, air lines, connections,
Radiator - Clean clamps, and seals. Make repairs, if necessary.
i02176881 •
Severe Service Application -
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The radiator is not usually supplied by Perkins. The
following text describes a typical cleaning procedure
for the radiator. Refer to the OEM information for
Check
further information on cleaning the radiator.
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Note: Adjust the frequency of cleaning according to
Severe service is the application of an engine that
the effects of the operating environment.
exceeds the current published standards for that
engine. Perkins maintains standards for the following
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Inspect the radiator for these items: Damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
engine parameters:
• Performance such as power range, speed range,

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and fuel consumption
A WARNING
• Fuel quality
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Personal injury can result from air pressure.

• Operational Altitude
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro- • Maintenance intervals
tective face shield and protective clothing.
• Oil selection and maintenance
Maximum air pressure at the nozzle must be less
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than 205 kPa (30 psi) for cleaning purposes. • Coolant type and maintenance
• Environmental qualities
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction Installation
to the fan's air flow. Hold the nozzle approximately
6 mm (0 .25 inch) away from the radiator fins . Slowly
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Refer to the standards for the engine or consult your

move the air nozzle in a direction that is parallel with Perkins dealer or your Perkins distributor in order to
the radiator tube assembly. This will remove debris determine if the engine is operating within the defined
that is between the tubes. parameters.
Pressurized water may also be used for cleaning . Severe service operation can accelerate component
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The maximum water pressure for cleaning purposes wear. Engines that operate under severe conditions
must be less than 275 kPa (40 psi). Use pressurized may need more frequent maintenance intervals in
water in order to soften mud. Clean the core from order to ensure maximum reliability and retention of
both sides. full service life.
Use a degreaser and steam for removal of oil and Due to individual applications, it is not possible
grease. Clean both sides of the core. Wash the core to identify all of the factors which can contribute
with detergent and hot water. Thoroughly rinse the to severe service operation . Consult your Perkins
core with clean water. dealer or your Perkins distributor for the unique
maintenance that is necessary for the engine.
If the radiator is blocked internally, refer to the OEM
Manual for information regarding flushing the cooling
system .
SEBU7833-01 73
Maintenance Section
Starting Motor - Inspect
The operating environment, incorrect operating Check the starting motor for correct operation . Check
procedures and incorrect maintenance procedures the electrical connections and clean the electrical
can be factors which contribute to a severe service connections. Refer to the Systems Operation , Testing
application. and Adjusting Manual, "Electric Starting System -
Test" for more information on the checking procedure
and for specifications or consult your Perkins dealer
Environmental Factors or your Perkins distributor for assistance.
Ambient temperatures - The engine may be
exposed to extended operation in extremely
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i02 184788
cold environments or hot environments. Valve
components can be damaged by carbon buildup if Turbocharger - Inspect
the engine is frequently started and stopped in very
cold temperatures. Extremely hot intake air reduces
. (If Equipped)
engine performance .
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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
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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
Buitdup - Compounds, elements, corrosive
chemicals and salt can damage some components.
Altitude - Problems can arise when the engine is E

efficiency.
If the turbocharger fails during engine operation,

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damage to the turbocharger compressor wheel
operated at altitudes that are higher than the intended
and/or to the engine may occur. Damage to the
settings for that application. Necessary adjustments
turbocharger compressor wheel can cause additional
should be made.
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damage to the pistons , the valves, and the cylinder

head.
Incorrect Operating Procedures
NOTICE
• Extended operation at low idle Turbocharger bearing failures can cause large quanti-
ties of oil to enter the air intake and exhaust systems.
• Frequent hot shutdowns Loss of engine lubricant can result in serious engine
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damage.
• Operating at excessive loads
Minor leakage of oil into a turbocharger under extend-
• Operating at excessive speeds ed low idle operation should not cause problems as
long as a turbocharger bearing failure has not oc-
Operating outside the intended application cured .
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Incorrect Maintenance Procedures When a turbocharger bearing failure is accompanied

by a significant engine performance loss (exhaust
Extending the maintenance intervals smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is renewed.
• Failure to use recommended fuel , lubricants and
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coolant/antifreeze A visual inspection of the turbocharger can minimize

unscheduled downtime. A visual inspection of the
i02177969 turbocharger can also reduce the chance for potential
damage to other engine parts.
Starting Motor - Inspect
Removal and Installation
Note: The turbochargers that are supplied are
Perkins recommends a scheduled inspection of the
non serviceable .
starting motor. If the starting motor fai ls , the engine
may not start in an emergency situation.
74 SEBU7833-01
Maintenance Section
Walk-Around Inspection
For options regarding the removal , installation, and • The guards must be in the correct place. Repair
replacement, consult your Perkins dealer or your damaged guards or replace missing guards .
Perkins distributor. Refer to the Disassembly and
Assembly Manual, "Turbocharger - Remove and Wipe all caps and plugs before the engine is
Turbocharger - Install" for further informalion . serviced in order to reduce the chance of system
contamination .
Inspecting
NOTICE
For any type of leak (coolant, lube, orfuel) clean up the
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NOTICE fluid. If leaking is observed , find the source and correct
The compressor housing for the turbocharger must the leak. If leaking is suspected, check the fluid levels
not be removed from the turbocharger for cleaning . more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
The actuator linkage is connected to the compressor unwarranted.
housing. If the actuator linkage is moved or disturbed
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the engine may not comply with emmissions legisla-
lion. NOTICE
Accumulated grease and/or oil on an engine is a fire
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hazard . Remove the accumulated grease and oil. Re-
1. Remove the pipe from the lurbocharger exhaust fer to this Operation and Maintenance Manual, "En-
outlet and remove the air intake pipe to the gine - Clean" for more information .
turbocharger. Visually inspect the piping for the
presence of oil. Clean the interior of the pipes
in order to prevent dirt from entering during • Ensure that the cooling system hoses are correctly
reassembly.
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2. Check for the presence of oil. If oil is leaking from
clamped and that the cooling system hoses are
tight. Check for leaks. Check the condition of all
pipes.
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the back side of the compressor wheel, there is a
possibility of a failed turbocharger oil seal. • Inspect the water pump for coolant leaks.
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The presence of oil may be the result of extended Note: The water pump seal is lubricated by the
engine operation at low idle . The presence of oil coolant in the cooling system . It is normal for a small
may also be the result of a restriction of the line amount of leakage to occur as the engine cools down
for the intake air (clogged air filters), which causes and the parts contract.
the turbocharger to slobber.
Excessive coolant leakage may indicate the need
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3. Inspect the bore of the housing of the turbine to replace the water pump seal. For the removal of
outlet for corrosion. the water pump and the installation of water pump
and/or seal , refer to the Disassembly and Assembly
4. Fasten the air intake pipe and the exhaust outlet Manual, "Water Pump - Remove and Install" for more
pipe to the turbocharger housing. information or consult your Perkins dealer or your
Perkins distributor.
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i02177973
Inspect the lubrication system for leaks at the front
Walk-Around Inspection crankshaft seal , the rear crankshaft seal, the oil
pan , the oil filters and the rocker cover.
Inspect the fuel system for leaks. Look for loose

fuel line clamps and/or tie-wraps .
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Inspect the Engine for Leaks and

for Loose Connections • Inspect the piping for the air intake system and the
elbows for cracks and for loose clamps. Ensure
A walk-around inspection should only take a few that hoses and tubes are not contacting other
minutes. When the time is taken to perform these hoses, tubes , wiri ng harnesses , etc.
checks , costly repairs and accidents can be avoided .
• Inspect the alternator belts and any accessory
For maximum engine service life , make a thorough drive belts for cracks , breaks or other damage.
inspeclion of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts , loose connections and
trash buildup . Make repairs , as needed :
SEBU7833-01 75
Maintenance Section
Water Pump - Inspect
Belts for multiple groove pulleys must be replaced as

matched sets . If only one belt is replaced , the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
• Drain the water and the sediment from the fuel

tank on a daily basis in order to ensure that only
clean fuel enters the fuel system.
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• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
Inspect the ground strap for a good connection and
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for good condition .
• Disconnect any battery chargers that are not
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protected against the current drain of the starting
motor. Check the condi tion and the electrolyte level
of the batteries, unless the engine is equipped with
a maintenance free battery.
• Check the condition of the gauges . Replace any

gauges that are cracked. Replace any gauge that
can not be calibrated . E
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i0 1907756
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Water Pump - Inspect
A failed water pump may cause severe engine

overheating problems that could result in the following
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conditions:
Cracks in the cylinder head
• A piston seizure
• Other potential damage to the engine

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Note: The water pump seal is lubricated by the

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

the water pump seal or the water pump if there
is an excessive leakage of coolant. Refer to the
Disassembly and Assembly Manual, "Water Pump
- Remove and Install" for the disassembly and
assembly procedure .
76 SEBU7833-01
Warranty Section
Warranty tnformation
Warranty Section
Warranty Information
i01903596
Emissions Warranty
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Information
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This engine may be certified to comply with exhaust
emission standards and gaseous emission standards
that are prescribed by the law at the time of
manufacture, and this engine may be covered by an
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Emissions Warranty. Consult your authorized Perkins
dealer or your authorized Perkins distributor in order
to determine if your engine is emissions certified and
if your engine is subject to an Emissions Warranty.
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SEBU7833-01 77
Index Section
Index
A E
After Starting Engine ........................................ .... 27 Electrical System ............ ...... ............. .................... 10
After Stopping Engine ............................................ 29 Grounding Practices .............................. ............. 11
Aftercooler Core - Clean/Test .................... ..... .. ..... 49 Emergency Stopping ............. ........ ........................ 29
Aftercooler Core - Inspect.. .. .. ..... ...... ........ .. .. ......... 49 Emissions Certification Film ................................ 18
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Alternator - Inspect ................................................ 50 Label for compliant engines ............... ................ 18
Alternator and Fan Belts - Inspect/Adjust/ Label for engines that are not compliant... ......... 19
Replace ......................................................... ..... 50 Emissions Warranty Information ............................ 76
Adjustment ............ .. ................ ........................... 50 Engine - Clean ....................................................... 57
Inspection ................................. .......................... 50 Engine Air Cleaner Element (Dual Element) -
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Replacement ........................... ... ... ..................... 50 Clean/Replace ........................... .......................... 58
Cleaning the Primary Air Cleaner Elements ...... 59
Servicing the Air Cleaner Elements ................... 58
B Engine Air Cleaner Element (Single Element) -
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Inspect/Replace ....................... ............................ 60
Battery - Replace .................... .... ........................... 51 Engine Air Cleaner Service Indicator - Inspect... ... 60
Battery Electrolyte Level - Check .......................... 51 Test the Service Indicator................................... 60
Battery or Battery Cable - Disconnect.. ................. 52 Engine Description ............................... ................. 15
Before Starting Engine .......... ............................ 9, 25
Burn Prevention ................... ... .......................... ....... 7
Batteries ................. ...................... ...... ......... .. ... .... 7
Coolant.. ............................................................... 7 E Engine Cooling and Lubrication .... .. ................... 17
Engine Service Life ............ ............ .................... 17
Engine Specifications .............................. ........... 15
Engine Ground - Inspect/Clean .. .................. ..... .... 61
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Oils ............................. .............. ....................... ..... 7 Engine Identification .............................................. 18
Engine Lifting .... ...... .... ...... ... .................. ............. ... 21
Engine Mounts - Inspect ........................................ 61
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c Engine Oil and Filter - Change .............................. 62

Drain the Eng ine Oil .... ..................... .................. 62
Cold Weather Operation ..................................... . 30 Fill the Engine Crankcase .................................. 64
Hints for Cold Weather Operation .................... .. 30 Replace the Element for the Oil Filter ............ .... 63
Idling the Engine ...................... ......................... 31 Replace the Spin-on Oil Filter ................... .. ...... 63
Recommendations for Coolant Warm Up .......... 31 Engine Oil Level - Check .......... ..... .............. .......... 61
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Recommendations for the Coolant .. ................ .. 30 Engine Oil Sample - Obtain ............................... .... 61
Viscosity of the Engine Lubrication OiL ............. . 30 Obtain the Sample and the Analysis .................. 62
Cold Weather Starting ........................................... 26 Engine Operation ................................................. 28
Cooling System Coolant - Change ........................ 55 Engine Starting ................................................ 10, 25
Cooling System Coolant (Commercial Heavy-Duty) - Engine Stopping .............................................. 10, 29
Change ......... ...................... .................... .... ......... 52 Engine Storage ..... ................... ..... ......................... 21
Drain ........................................... ... ........... ......... 52 Cooling System ................................. ............ ..... 22
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Fill .......................... ............................................ 53 Exhaust System ............................... .................. 22

FI~h .......... ............... ..... .................................... ~ General Items .. ................... .. ............................. 23
Cooling System Coolant (ELC) - Change .............. 54 Induction System .......................... ...... ...... ......... 22
Drain .................................................................. 54 Lubrication System ....................................... ..... 21
Fill ...................................................................... 55 Engine Valve Lash - Inspect/Adjust ....................... 64
Rush ........................... ..................... .................. M Engine Warm-up ..................... .... ........................... 28
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Cooling System Coolant Extender (ELC) - Add ..... 56

Cooling System Coolant Level - Check .. .......... ..... 56
Engines With a Coolant Recovery Tank ............. 56 F
Engines Without a Coolant Recovery Tank ...... .. 56
Crushing Prevention and Cutting Prevention .......... 9 Fire Prevention and Explosion Prevention .............. 7
Fire Extinguisher ............ ......... .. ........................... 8
Lines, Tubes and Hoses ................ ...................... 9
D Fluid Recommendations ............. ........................... 35
Cooling System Specifications ........................... 42
Driven Equipment - Check .................................... 57 ELC Cooling System Maintenance .......... ........ .. 44
Engine Oil .......................................................... 36
Fuel Specifications ..... ....... .............. .. ........... ...... 39
General Lubricant Information ........................... 35
78 SEBU7833-01
'I I I Index Section
Foreword ................................................................ 4 Model View Illustrations ...................................... .. . 12

California Proposition 65 Warning ....................... 4 1103 Engine Model Views ................................. . 14
Literature Information .......... ......................... ..... ... 4 1104 Engine Model Views ............................... 12
Maintenance .......................... ......... ........... ... ....... 4 Model Views .................................... .. .. .................. 12
Maintenance Intervals ................... .. .... ....... ........ .. 4 Mounting and Dismounting .................. .................... 9
Operation ....... ...................................................... 4
Overhaul .............................................................. 4
Safety ............. ... .. ..... ............ ..... .. .... ..................... 4 o
Fuel and the Effect from Cold Weather ................. 32
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Fuel Conservation Practices .... ............ .................. 28 Operation Section .................. ............................... 21
Fuel Injector - Test/Change ................................... 64
Removal and Installation of the Fuel Injectors ... 65
Fuel Related Components in Cold Weather ...... .... 33 p
Fuel Filters .............................................. ........... 33
Fuel Heaters .............. ...................... .... .. ........ .... 33 Product Identification Information ......................... 18
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Fuel Tanks ... .. ............ .................... ........ ............. 33 Product Information Section ......................... ......... 12
Fuel System - Prime ................ ...... .......... .. ...... ...... 65
Fuel System Primary Filter (Water Separator)
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Element - Replace ................ .... .................... .... ... 67 R
Fuel System Primary FilterlWater Separator -
Drain .. .... ... ... ....... ........... .......... .............. .. .. ...... .... 66 Radiator - Clean ......................... .......... ........ ........ 72
Fuel System Secondary Filter - Replace ............... 68 Reference Numbers .......... .................................... 18
Element filter .... ........ .................. ........................ 68 Record for Reference ......................................... 18
Spin-on filter ..... ... ............................................... 69
Fuel Tank Water and Sediment - Drain ................. 70
Drain the Water and the Sediment... .......... .... .... 70 E Refill Capacities .............. ... ... ......................... ........
Cooling System ........................... ...... ......... .. ......
Lubrication System ................................ .... ........
34
34
34
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Fuel Storage Tanks ............................................ 70
Fuel Tank ...... .................................. .............. ..... 70
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G Safety Messages ....... ... ............................. .. ............ 5

Safety Section ........................ ................ .. .. ............ 5
Gauges and Indicators ............ .. ........ .................... 24 Serial Number Plate ................................ .............. 18
'j General Hazard Information .................................... 5 Severe Service Application - Check ...................... 72
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Containing Fluid Spillage ...... ...... ................ ......... 6
Fluid Penetration ... ............................................... 6
Environmental Factors .......... .................. ........... 73
In correct Maintenance Procedures ............ ........ 73
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Pressure Air and Water .. .. ................. .. .... .... ......... 6 Incorrect Operating Procedures ................ ......... 73
Starting Motor - Inspect.. ................ ...... .. ...... ......... 73
Starting the Engine ........................................ ........ 26
H Starting with Jump Start Cables ............................ 27
Stopping the Engine .................. .............. ............. 29
Hoses and Clamps - Inspect/Replace .......... ......... 71
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Replace the Hoses and the Clamps .................. 71

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Table of Contents ..................................................... 3

Turbocharger - Inspect (If Equipped) .................. .. . 73
Important Safety Information .. ........ .... .. .. .. .. ............ 2 Inspecting ........... ...... .... .............. ..... ... .. .............. 74
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Removal and Installation ................................ .... 73
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Lifting and Storage ........ ...... .................. ................ 21
Walk-Around Inspection ... .. ...................... .. .......... 74
Inspect the Engine for Leaks and for Loose
M Connections .......................................... .. .. ...... 74
Warranty Information ............................................. 76
Maintenance Interval Schedule ................ ............ 48 Warranty Section ................ ....... ............................ 76
Maintenance Section .. .. ........ .. .. ...................... .. .... . 34 Water Pump - Inspect. .... .... .. ........ ......................... 75
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
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Model: _____________________________________________________________________
Product Identification Number: _ _ _ _ __ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
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Engine Serial Number: _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ ___
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Transmission Serial Number: _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Generator Serial Number: _ _ _ _ _ _ _ _ __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
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Attachment Serial Numbers: _ __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Attachment Information: _ _ _ __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
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Customer Equipment Number: _ _ _ _ _ _ __ _ __ _ _ _ _ _ _ __ __ _ _ _ _ _ __
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Dealer Equipment Number: _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Dealer Information
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Name: Branch: _ _ _ _ _ _ _ _ _ _ _ _ _ __
Address:
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Dealer Contact Phone Number Hours

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Sales:
Parts:
Service:
LY
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O
E
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EN
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EF
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©2004 Perkins Engines Company Limited

All RiQhts Reserved Printed in U.S.A.
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EF
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EN
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Asia
Perkins Engines (Asia Pacific) Pte Ltd
7 Tractor Road
LY
Singapore 627968
Telephone +65 6828 7469
Fax +65 6828 7414
Europe, Middle East and Africa
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Perkins Engines Company Limited
Peterborough PE1 5NA
United Kingdom
Telephone +44 (0)1733 583000
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Fax +44 (0)1733 582240
North America
Perkins Engines Inc
N4 AC 6160
PO Box 610
Mossville, IL 61552 -0610, USA
1-888-PERK-ENG E
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Telephone + 1 309 578 7364
Fax +1 309 578 7329
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Latin America
Perkins Motores do Brasil Ltda
Rua Alexandre Dumas, 1711 Ed. Birman 11 , 9' andar
Chacara Santo Antonio
Sao Paulo I SP - Brasil
Cep: 04717-004
Telephone +55 11 2109 2038
ER
Fax +55 11 2109 2089

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~Perkins®
www.perkins.com
All information in this document is substanlially correct at time of prinling and may be alLered subsequently by the company

Operation and Maintenance Manual Perkins

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117765

11 11111 11 111 1111111 111111111111111111111111

Models DC, DO, OF, DG, OJ, OK,

the State of California to cause cancer, birth defects, and other

Important Safety Information

The meaning of this safety alert symbol is as follows:

replacement parts or parts with equivalent

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

Burn Prevention .. ............................. ....................... 7

Fire Prevention and Explosion Prevention .............. 7

Before Starting Engine .... .... .......... ..................... 9

Engine Starting .................................................... 10

Engine Stopping ............... .....•... ........................... 10

Product Information Section

Product Identification Information ........................ 18

Lifting and Storage ... ... ........................ ......... ......... 21

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

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

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

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

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

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

Foreword Recommended service should be performed at the

Your authorized Perkins dealer or your Perkins

Major engine overhaul details are not covered in

through procedures of inspecting , starting, operating

Safety Section Ether

sign on the replacement part. Perkins dealers or

Do not work on the engine and do not operate the

the instructions or failure to heed the warnings could

The warning labels that may be found on the engine

Attach a "Do Not Operate" warning tag or a similar

repair the equipment.

The maximum air pressure for cleaning purposes

(i) 'd Fluid Penetration

Make sure that all protective guards and all covers

Never put maintenance fluids into glass containers.

Obey all local regulations for the disposal of liquids.

before you work on the bus bar or the glow plugs .

servicing position . are contained du ring performance of inspection ,

Obey all local regulations for the disposal of liquids. i02203164

Fire Prevention and Explosion

Any contact with hot coolant or with steam can cause

and the engine has been allowed to cool. damage.

Determine whether the engine will be operated in an

Batteries the engine. Do not allow any flammable combustible

Do not expose the engine to any flame.

Do not weld on lines or tanks that conta in flammable

Wiring must be kept in good condition. All electrical

Arcing or sparking could cause a fire . Secure

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

The filter housings must be tightened to the correct

Do not charge a frozen battery. This may cause an

The batteries must be kept clean. The covers

Repair any lines that are loose or damaged. Leaks

• Outer coverings are ballooning .

Do not stand on components which cannot support

Do not carry tools or supplies when you mount the

Before Starting Engine