Refill Capacities

Fluid Recommendations

Table 14

In order to maintain the correct balance between the

antifreeze and the additives, you must maintain the

recommended concentration of ELC. Lowering the

proportion of antifreeze lowers the proportion of

additive. This action will lower the ability of the

coolant to protect the system from pitting, from

cavitation, from erosion, and from deposits.

Coolant Service Life

Coolant Type

Service Life  (1)

6,000 Service Hours or Three

Years

Perkins  ELC

Commercial Heavy-Duty Anti-

freeze that meets ASTM

D6210

NOTICE

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

system that is filled with Extended Life Coolant (ELC).

3000 Service Hours or Two Years

A Perkins approved SCA

inhibitor

3000 Service Hours or Two Years

Do not  use  standard supplemental  coolant additive

(SCA).

(1)

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

be flushed out at this time.

When using Perkins ELC, do not use standard SCA's

or SCA filters.

ELC

Perkins  provides ELC for use in the following

applications:

ELC Cooling System Cleaning

•   Heavy-duty spark ignited gas engines

•   Heavy-duty diesel engines

•   Automotive applications

Note: If the cooling system is already using ELC,

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

coolant or by cooling system damage.

The anti-corrosion package for ELC is different from

the anti-corrosion package for other coolants. ELC is

an ethylene glycol base coolant. However, ELC

contains organic corrosion inhibitors and antifoam

agents with low amounts of nitrite. Perkins ELC has

been formulated with the correct amount of these

additives in order to provide superior corrosion

protection for all metals in engine cooling systems.

Clean water is the only cleaning agent that is required

when ELC is drained from the cooling system.

Before the cooling system is filled, the heater control

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

to the OEM in order to set the heater control. After the

cooling system is drained and the cooling system is

refilled, operate the engine until the coolant level

reaches the normal operating temperature and until

the coolant level stabilizes. As needed, add the

coolant mixture in order to fill the system to the

specified level.

ELC is available in a premixed cooling solution with

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

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

The Premixed ELC is recommended for the initial fill

of the cooling system. The Premixed ELC is also

recommended for topping off the cooling system.

Changing to Perkins  ELC

Containers of several sizes are available. Consult

your Perkins  distributor for the part numbers.

To change from heavy-duty antifreeze to the Perkins

ELC, perform the following steps:

ELC Cooling System Maintenance

NOTICE

Correct additions to the Extended Life

Coolant

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

tained  during   performance  of  inspection,   mainte-

nance,   testing,  adjusting   and  the   repair   of  the

product. Be prepared to collect the fluid with  suitable

containers before opening any compartment or disas-

sembling any component containing fluids.

NOTICE

Use only  Perkins products for pre-mixed  or concen-

trated coolants.

Dispose of all fluids according to local regulations and

mandates.

Mixing Extended Life Coolant with other products re-

duces the Extended Life  Coolant service life. Failure

to  follow the  recommendations  can reduce  cooling

system components life unless appropriate corrective

action is performed.

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to local

regulations.

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3. Flush the system with clean water in order to

remove any debris.

•   Drain the cooling system into a suitable container.

Dispose of the coolant according to local

regulations. Flush the system with clean water. Fill

the system with the Perkins  ELC.

4. Use Perkins  cleaner to clean the system. Follow

the instruction on the label.

•   Drain a portion of the cooling system into a

suitable container according to local regulations.

Then, fill the cooling system with premixed ELC.

This procedure should lower the contamination to

less than 10 percent.

5. Drain the cleaner into a suitable container. Flush

the cooling system with clean water.

6. Fill the cooling system with clean water and

operate the engine until the engine is warmed to

49° to 66°C (120° to 150°F).

•   Maintain the system as a conventional Heavy-Duty

Coolant. Treat the system with an SCA. Change

the coolant at the interval that is recommended for

the conventional Heavy-Duty Coolant.

NOTICE

Incorrect or incomplete flushing of the cooling system

can  result  in  damage  to  copper  and  other  metal

components.

Commercial Heavy-Duty Antifreeze and

SCA

To avoid damage to the cooling system, make sure to

completely flush the cooling system with  clear water.

Continue to flush the system until all the  signs of the

cleaning agent are gone.

NOTICE

Commercial   Heavy-Duty  Coolant   which   contains

as  part of  the  corrosion protection  system

Amine

must not be used.

7. Drain the cooling system into a suitable container

and flush the cooling system with clean water.

NOTICE

Never operate  an engine without  water temperature

regulators in the  cooling system. Water  temperature

regulators help to maintain the  engine coolant at the

correct operating temperature. Cooling  system prob-

Note: The cooling system cleaner must be thoroughly

flushed from the cooling system. Cooling system

cleaner that is left in the system will contaminate the

coolant. The cleaner may also corrode the cooling

system.

lems

can

develop

without

water

temperature

regulators.

8. Repeat Steps 6 and repeat steps 7 until the system

is completely clean.

Check the antifreeze (glycol concentration) in order to

ensure adequate protection against boiling or

freezing. Perkins recommends the use of a

refractometer for checking the glycol concentration. A

hydrometer should not be used.

9. Fill the cooling system with the Perkins Premixed

ELC.

ELC Cooling System Contamination

Perkins  engine cooling systems should be tested at

500 hour intervals for the concentration of SCA.

NOTICE

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

An SCA that is liquid may be needed at 500 hour

intervals.

Mixing ELC with other products reduces the effective-

ness of  the ELC and  shortens the  ELC service life.

Use only  Perkins Products  for premixed or  concen-

trate coolants.  Failure to follow  these recommenda-

Adding the SCA to Heavy-Duty Coolant at

the Initial Fill

tions

can   result   in    shortened   cooling   system

component life.

Commercial heavy-duty antifreeze that meets ASTM

D4985 specifications MAY require an addition of SCA

at the initial fill. Read the label or the instructions that

are provided by the OEM of the product.

ELC cooling systems can withstand contamination to

a maximum of 10 percent of conventional heavy-duty

antifreeze or SCA. If the contamination exceeds 10

percent of the total system capacity, perform ONE of

the following procedures:

Use the equation that is in Table 15  to determine the

amount of Perkins  SCA that is required when the

cooling system is initially filled.

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Table 15

Cleaning the System of Heavy-Duty

Antifreeze

Equation For Adding The SCATo The Heavy-Duty Coolant At

The Initial Fill

Perkins  cooling system cleaners are designed to

clean the cooling system of harmful scale and

corrosion. Perkins  cooling system cleaners dissolve

mineral scale, corrosion products, light oil

contamination, and sludge.

V × 0.045 = X

V is the total volume of the cooling system.

X is the amount of SCA that is required.

•   Clean the cooling system after used coolant is

drained or before the cooling system is filled with

new coolant.

Table 16 is an example for using the equation that is

in Table 15 .

Table 16

Example Of The Equation For Adding The SCATo The Heavy-

Duty Coolant At The Initial Fill

•   Clean the cooling system whenever the coolant is

contaminated or whenever the coolant is foaming.

Total Volume of the

Cooling System (V)

Multiplication

Factor

Amount of SCA

that is Required (X)

i04129134

15 L (4 US gal)

× 0.045

0.7 L (24 oz)

Fluid Recommendations

Adding The SCA to The Heavy-Duty

Coolant For Maintenance

General Lubricant Information

Because of government regulations regarding the

certification of exhaust emissions from the engine, the

lubricant recommendations must be followed.

Heavy-duty antifreeze of all types REQUIRE periodic

additions of an SCA.

Test the antifreeze periodically for the concentration

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

Maintenance Manual, “Maintenance Interval

Schedule” (Maintenance Section). Test the

concentration of SCA.

•   API

American Petroleum Institute

Society Of Automotive Engineers Inc.

Association des Constructers

•   SAE

•   ACEA

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

The size of the cooling system determines the

amount of SCA that is needed.

European Automobiles .

•   ECF-3

Engine Crankcase Fluid

Use the equation that is in Table 17  to determine the

amount of Perkins  SCA that is required, if

necessary:

Licensing

Table 17

The Engine Oil Licensing and Certification System

by the American Petroleum Institute (API)  and the

Association des Constructers European

Automobilesand (ACRA) is recognized by Perkins .

For detailed information about this system, see the

latest edition of the API publication No. 1509. Engine

oils that bear the API symbol are authorized by API.

Equation For Adding The SCATo The Heavy-Duty Coolant For

Maintenance

V × 0.014 = X

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Table 18 is an example for using the equation that is

in Table 17 .

Table 18

Example Of The Equation For Adding The SCATo The Heavy-

Duty Coolant For Maintenance

Total Volume of the

Cooling System (V)

Multiplication

Factor

Amount of SCA

that is Required (X)

15 L (4 US gal)

× 0.014

0.2 L (7 oz)

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The chemical limits were developed in order to

maintain the expected life of the engine

aftertreatment system. The performance of the

engine aftertreatment system can be adversely

affected if oil that is not specified in table 19  is used.

The life of your Aftertreatmentsystem is defined by

the accumulation of ash on the surface of the filter.

Ash is the inert part of the particulate matter. The

system is designed in order to collect this particulate

matter. There is a very small percentage of particulate

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

matter will eventually block the filter, causing loss of

performance and increased fuel consumption. Most

of the ash comes from the engine oil which is

gradually consumed during normal operation. This

ash is passes through the exhaust. To meet the

designed life of the product, the use of the

appropriate engine oil is essential. The oil

Illustration 39

g01987816

Typical API symbol

specification that is listed in table 19  has low ash

content.

Terminology

Maintenance intervals for engines that use

biodiesel – The oil change interval can be adversely

affected by the use of biodiesel. Use oil analysis in

order to monitor the condition of the engine oil. Use

oil analysis also in order to determine the oil change

interval that is optimum.

Certain abbreviations follow the nomenclature of SAE

J754. Some classifications follow SAE J183

abbreviations, and some classifications follow the

EMA Recommended Guideline on Diesel Engine Oil.

In addition to Perkins  definitions, there are other

definitions that will be of assistance in purchasing

lubricants. Recommended oil viscosities can be

found in this publication, “Fluid Recommendations/

Engine Oil” topic (Maintenance Section).

Note: These engine oils are not approved by

Perkins  and these engine oils must not be used:

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

Engine Oil

Lubricant Viscosity Recommendations

for Direct Injection (DI) Diesel Engines

Commercial Oils

NOTICE

The correct SAE viscosity grade of oil is determined

by the minimum ambient temperature during cold

engine start-up, and the maximum ambient

temperature during engine operation.

Perkins require the use of the following specifica-

tion of  engine oil. Failure  to use the  appropriate

specification of  engine oil will  reduce the  life of

your engine. Failure to use the appropriate speci-

fication of  engine oil  will also  reduce the life  of

your aftertreatment system.

Refer to illustration40 (minimum temperature) in

order to determine the required oil viscosity for

starting a cold engine.

Table 19

Refer to illustration 40 (maximum temperature) in

order to select the oil viscosity for engine operation at

the highest ambient temperature that is anticipated.

Classifications for the 400F IndustrialEngines

Oil Specification

Generally, use the highest oil viscosity that is

available to meet the requirement for the temperature

at start-up.

CJ-4

ACEA E9

ECF-3

API CJ-4 and ACEA E9 oil categories have the

following chemical limits:

•   0.1 percent maximum sulfated ash

•   0.12 percent maximum phosphorous

•   0. 4 percent maximum sulfur

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•   See the appropriate “Lubricant Viscosities”. Refer

to the illustration 40 in order to find the correct oil

viscosity grade for your engine.

•   At the specified interval, service the engine. Use

new oil and install a new oil filter.

•   Perform maintenance at the intervals that are

specified in the Operation and Maintenance

Manual, “Maintenance Interval Schedule”.

Oil analysis

Some engines may be equipped with an oil sampling

valve. If oil analysis is required, the oil sampling valve

is used to obtain samples of the engine oil. The oil

analysis will complement the preventive maintenance

program.

The oil analysis is a diagnostic tool that is used to

determine oil performance and component wear

rates. Contamination can be identified and measured

by using oil analysis. The oil analysis includes the

following tests:

Illustration 40

g02932046

Lubricant Viscosities

•   The Wear Rate Analysis monitors the wear of the

engines metals. The amount of wear metal and

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

increase in the rate of engine wear metal in the oil

is as important as the quantity of engine wear

metal in the oil.

Supplemental heat is recommended for cold soaked

starts below the minimum ambient temperature.

Supplemental heat may be required for cold soaked

starts that are above the minimum temperature that is

stated, depending on the parasitic load and other

factors. Cold soaked starts occur when the engine

has not been operated for a period of time. This

interval will allow the oil to become more viscous due

to cooler ambient temperatures.

•   Tests are conducted in order to detect

contamination of the oil by water, glycol, or fuel.

Aftermarket Oil Additives

•   The Oil Condition Analysis determines the loss of

the oils lubricating properties. An infrared analysis

is used to compare the properties of new oil to the

properties of the used oil sample. This analysis

allows technicians to determine the amount of

deterioration of the oil during use. This analysis

also allows technicians to verify the performance

of the oil according to the specification during the

entire oil change interval.

Perkins  does not recommend the use of aftermarket

additives in oil. It is not necessary to use aftermarket

additives in order to achieve the engines maximum

service life or rated performance. Fully formulated,

finished oils consist of base oils and of commercial

additive packages. These additive packages are

blended into the base oils at precise percentages in

order to help provide finished oils with performance

characteristics that meet industry standards.

There are no industry standard tests that evaluate the

performance or the compatibility of aftermarket

additives in finished oil. Aftermarket additives may not

be compatible with the finished oils additive package,

which could lower the performance of the finished oil.

The aftermarket additive could fail to mix with the

finished oil. This failure could produce sludge in the

crankcase. Perkins  discourages the use of

aftermarket additives in finished oils.

To achieve the best performance from a Perkins

engine, conform to the following guidelines:

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i04057529

Satisfactory engine performance is dependent on the

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

fuel will give the following results: long engine life and

acceptable exhaust emissions levels . The fuel must

meet the minimum requirements that are stated in the

table 20 .

Fluid Recommendations

•   Glossary

NOTICE

•   ISO International Standards Organization

The footnotes are of the  key part Perkins  Specifica-

tion for Distillate Diesel  Fuel Table. Read ALL of  the

footnotes.

•   ASTMAmerican Society for Testing and Materials

•   HFRRHigh Frequency Reciprocating Rig for

Lubricity  testing of diesel fuels

•   FAMEFatty Acid Methyl Esters

•   CFRCo-ordinating Fuel Research

•   ULSDUltra Low Sulfur Diesel

•   RMERape Methyl Ester

•   SMESoy Methyl Ester

•   EPA Environmental Protection Agency of the

United States

•   PPM Parts Per Million

•   DPF Diesel Particulate Filter

General Information

NOTICE

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

information. By use  of this document you agree  that

Perkins Engines Company Limited is not responsible

for errors or omissions.

NOTICE

These recommendations are subject to change  with-

out notice. Contact your  local Perkins  distributor  for

the most up-to-date recommendations.

The fuel information within this OMM is for use with

the following engine models: 403F-15T, 404F-22,

404F-22T, and 404F-22TA

Diesel Fuel Requirements

Perkins  is not in a position to continuously evaluate

and monitor all worldwide distillate diesel fuel

specifications that are published by governments and

technological societies.

The Perkins table for Specification for Distillate

Diesel Fuel provides a known reliable baseline in

order to judge the expected performance of distillate

diesel fuels that are derived from conventional

sources.

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Table 20

Perkins Specification for DistillateDiesel Fuel(1)

Property

UNITS

Requirements

ASTMTest

ISOTest

Aromatics

Ash

%Volume

%Weight

35% maximum

D1319

D482

ISO3837

ISO6245

0.01% maximum

Carbon Residue on 10%

Bottoms

%Weight

0.35% maximum

D524

ISO4262

Cetane Number  (2)

Cloud Point

-

40 minimum

D613/D6890

ISO5165

ISO3015

°C

The cloud point must not ex-  D2500

ceed the lowest expected

ambient temperature.

Copper Strip Corrosion

-

No. 3 maximum

D130

ISO2160

Density at 15 °C (59 °F)(3)   Kg / M

3

801 minimum and 876

maximum

No equivalent test

ISO 3675ISO 12185

ISO3405

Distillation

°C

10% at 282 °C (539.6 °F)

maximum

D86

90% at 360 °C (680 °F)

maximum

Flash Point

°C

-

legal limit

D93

ISO2719

Thermal Stability

Minimum of 80% reflectance D6468

after aging for 180 minutes

at 150 °C (302 °F)

No equivalent test

Pour Point

°C

6 °C (42.8 °F) minimum be-  D97

low ambient temperature

ISO3016

Sulfur  (1)

%mass

0.0015

D5453/D26222

ISO 20846ISO 20884

ISO3405

Kinematic Viscosity  (4)

2

“MM” “/S (cSt)”

The viscosity of the fuel that D445

is delivered to the fuel injec-

tion pump. “1.4 minimum/

4.5 maximum”

Water and sediment

Water

% weight

% weight

% weight

mg/100mL

0.1% maximum

0.1% maximum

0.05% maximum

D1796

D1744

D473

ISO3734

No equivalent test

ISO3735

Sediment

Gums and Resins  (5)

10 mg per 100 mL

maximum

D381

ISO6246

Lubricity corrected wear

mm

0.52 maximum

D6079

ISO12156-1

scar diameter at 60 °C

(140 °F).  (6)

(1)

This specification includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to

ASTM D5453, ASTM D2622, or ISO 20846, ISO 20884 test methods.

(2)

(3)

A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather.

“Via standards tables, the equivalent API  gravity for the minimum density of 801 kg / m  (kilograms per cubic meter) is 45 and for the maximum

3

density of 876 kg / m is 30”.

3

(4)

The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscosity

requirementand the fuel should meet the maximum viscosity requirements at 40 °C  (104 °F) of either the ASTM D445 test method or the ISO

3104 test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain “1.4 cSt”or greater viscosity at the fuel in-

jection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to “1.4 cSt” at the fuel injection pump.

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

The lubricity of a fuel is a concern with ultra low sulfur fuel. To determine the lubricity of the fuel, use the ISO 12156-1 or ASTM D6079 High

Frequency Reciprocating Rig (HFRR) test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supplier. Do not

treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system.

(5)

(6)

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Engines that are manufactured by Perkins  are

certified with the fuel that is prescribed by the United

States Environmental Protection Agency. Engines

that are manufactured by Perkins are certified with

the fuel that is prescribed by the European

Certification. Perkins does not certify diesel engines

on any other fuel.

Note: The owner and the operator of the engine has

the responsibility of using the fuel that is prescribed

by the EPA and other appropriate regulatory

agencies.

NOTICE

Operating with fuels that do not meet the Perkins  rec-

ommendations can cause the following effects: Start-

ing  difficulty, poor  combustion,  deposits in  the  fuel

injectors, reduced service life of  the fuel system, de-

posits in the combustion chamber and reduced  serv-

ice life of the engine.

The Perkins 400F diesel engines must be operated

using Ultra Low Sulfur Diesel. The sulphur content of

this fuel must be lower than 15 PPM. This fuel

complies with the emissions regulations that are

prescribed by the Environmental Protection Agency

of the United States

The fuels that are listed in the table 21  are

acceptable to use on all 400F engines.

Table 21

Acceptable Fuel Specification for the 400F Engines(1)

Fuel Specification

EN590

Comments

European Automotive Diesel Fuel (DERV)

ASDM D975 GRADE 1D S15

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

level”

ASTM D975 GRADE 2D S15

JIS K2204

“North American Middle Distillate general purpose Diesel fuel with less

than 15 PPM sulfur level”

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

the section “Lubricity”.

BS 2869 or equivalent

“EU Off Road Diesel fuel. Acceptable from 2011 MUST have less than

10 PPM sulfur level”

(1)

All the fuels must comply with the specification in the table for the Perkins Specification DistillateDiesel Fuel .

Diesel Fuel Characteristics

Cetane numbers in excess of 45 are normally

expected from current diesel fuel. However, a cetane

number of 40 may be experienced in some territories.

The United States of America is one of the territories

that can have a low cetane value. A minimum cetane

value of 40 is required during average starting

conditions. A fuel with higher cetane number is

recommended for operations at high altitudes or in

cold-weather operations.

Cetane Number

Fuel that has a high cetane number will give a shorter

ignition delay. A high cetane number will produce a

better ignition quality. Cetane numbers are derived for

fuels against proportions of cetane and

heptamethylnonane  in the standard CFR engine.

Refer to ISO 5165 for the test method.

Fuel with a low cetane number can be the root cause

of problems during a cold start.

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Viscosity

By using the test methods ASTM D5453, ASTM

D2622, or ISO 20846 ISO 20884, the content of sulfur

in ultra low sulfur (ULSD) fuel must be below 15 PPM

0.0015%. The lubricity of these fuels must not exceed

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

fuel lubricity test must be performed on an HFRR,

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

Viscosity is the property of a liquid of offering

resistance to shear or flow. Viscosity decreases with

increasing temperature. This decrease in viscosity

follows a logarithmic relationship for normal fossil

fuel. The common reference is to kinematic viscosity.

kinematic viscosity is the quotient of the dynamic

viscosity that is divided by the density. The

determination of kinematic viscosity is normally by

readings from gravity flow viscometers at standard

temperatures. Refer to ISO 3104 for the test method.

Lubricity

Lubricity is the capability of the fuel to prevent pump

wear. The fluids lubricity describes the ability of the

fluid to reduce the friction between surfaces that are

under load. This ability reduces the damage that is

caused by friction. Fuel injection systems rely on the

lubricating properties of the fuel. Until fuel sulfur limits

were mandated, the fuels lubricity was generally

believed  to be a function of fuel viscosity.

The viscosity of the fuel is significant because fuel

serves as a lubricant for the fuel system components.

Fuel must have sufficient viscosity in order to

lubricate the fuel system in both extremely cold

temperatures and extremely hot temperatures . If the

kinematic viscosity of the fuel is lower than “1.4 cSt”

at the fuel injection pump, damage to the fuel injection

pump can occur. This damage can be excessive

scuffing and seizure. Low viscosity may lead to

difficult hot restarting, stalling, and loss of

The lubricity has particular significance to the current

low viscosity fuel , low sulfur fuel, and low aromatic

fossil  fuel. These fuels are made in order to meet

stringent exhaust emissions. A test method for

measuring the lubricity of diesel fuels has been

developed and the test is based on the HFRR method

that is operated at 60°C (140°F). Refer to ISO 12156

part 1 and CEC document F06-A-96 for the test

method.

performance. High viscosity may result in seizure of

the pump.

Perkins  recommends kinematic viscosities of 1.4 and

4.5 mm2/sec that is delivered to the fuel injection

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

the fuel may be required to maintain 1.4 cSt or

greater viscosity at the fuel injection pump. Fuels with

a high viscosity might require fuel heaters in order to

lower the viscosity to 4.5 cSt at the fuel injection

pump.

Lubricity wear scar diameter of 0.52 mm

(0.0205 inch) MUST NOT be exceeded. The fuel

lubricity test must be performed on an HFRR,

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

Distillation

Density

Distillation is an indication of the mixture of different

hydrocarbons in the fuel. A high ratio of light weight

hydrocarbons can affect the characteristics of

combustion.

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

specific temperature. This parameter has a direct

influence on engine performance and a direct

influence on emissions. This influence determines

from a heat output given injected volume of fuel. This

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

(59 °F).

Recommendation for Biodiesel

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

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

made from various feedstock. The most commonly

available biodiesel in Europe is Rape Methyl Ester

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

Soy Methyl Ester (SME) is the most common

biodiesel in the United States. This biodiesel is

derived from soybean oil . Soybean oil or rapeseed

oil  are the primary feedstocks. These fuels are

together known as Fatty Acid Methyl Esters (FAME) .

Perkins  recommends a value of density of 841 kg/m

in order to obtain the correct power output. Lighter

fuels are acceptable but these fuels will not produce

the rated power.

Sulfur

The level of sulfur is governed by emissions

legislations . Regional regulation, national

regulations, or international regulations can require a

fuel with a specific sulfur limit. The sulfur content of

the fuel and the fuel quality must comply with all

existing local regulations for emissions.

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SEBU8609

69

Refill Capacities

Fluid Recommendations

Raw pressed vegetable oils are NOTacceptable for

use as a fuel in any concentration in compression

engines . Without esterification, these oils solidify in

the crankcase and the fuel tank. These fuels may not

be compatible with many of the elastomers that are

used in engines that are manufactured today. In

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

fuel in compression engines . Alternate base stocks

for biodiesel may include animal tallow, waste

cooking oils , or various other feedstocks. In order to

use any of the products that are listed as fuel, the oil

must be esterified .

Perkins  recognizes the fact that additives may be

required in some special circumstances. Contact your

fuel supplier for those circumstances when fuel

additives are required. Your fuel supplier can

recommend the appropriate fuel additive and the

correct level of treatment.

Note: For the best results, your fuel supplier should

treat the fuel when additives are required. The treated

fuel must meet the requirements that are stated in

table 20 .

Perkins  Diesel Fuel System Cleaner

Fuel made of 100 percent FAME is generally referred

to as B100 biodiesel or neat biodiesel.

Perkins  T400012 Fuel Cleaner is the only fuel

Biodiesel can be blended with distillate diesel fuel.

The blends can be used as fuel. The most commonly

available biodiesel blends are B7, which is 7 percent

biodiesel and 95 percent distillate diesel fuel.

cleaner that is recommended by Perkins .

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

Perkins  require the use of Perkins  fuel cleaner. The

use of the fuel is in order to remove deposits within

the fuel system that is created with the use of

biodiesel. For more information on the use of

biodiesel and biodiesel blends refer to

Note: The percentages given are volume-based.

The U.S. distillate diesel fuel specification ASTM

D975-09a includes up to B5 (5 percent) biodiesel.

“Recommendation for Biodiesel”.

European distillate diesel fuel specification EN590

includes up B7 (7 percent) biodiesel. Any diesel fuel

in Europe may contain up to B5 or in some regions up

to B7 biodiesel fuel.

Perkins  fuel cleaner will remove deposits that can

form in the fuel system with the use of biodiesel and

biodiesel blends. These deposits can create a loss of

power and engine performance.

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

deposits within the fuel system are removed after 30

hours of engine operation. For maximum results,

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

Perkins  fuel cleaner can be used on an on-going

basis with no adverse impact on engine or fuel

system durability.

Note: Engines that are manufactured by Perkins  are

certified by use of the prescribed Environmental

Protection Agency (EPA) and European Certification

fuels. Perkins does not certify engines on any other

fuel. The user of the engine has the responsibility of

using the correct fuel that is recommended by the

manufacturer and allowed by the EPA and other

appropriate regulatory agencies.

Details instruction on the rate of which the fuel

cleaner must be use are on the container.

Fuel for Cold Weather Operation

Note: Perkins  fuel cleaner is compatible with

existing and U.S. EPATier 4 nonroad certified diesel

engine emission control catalysts and particulate

filters. Perkins  fuel system cleaner contains less

than 15 ppm of sulfur and is acceptable for use with

ULSD fuel.

The European standard EN590 contains climate

dependant requirements and a range of options. The

options can be applied differently in each country.

There are five classes that are given to arctic climates

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

Fuel that complies with EN590 CLASS 4 can be used

at temperatures as low as −44 °C (−47.2 °F). Refer

to EN590 for a detailed discretion of the physical

properties of the fuel.

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

States of America may be used in very cold

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

Aftermarket Fuel Additives

Supplemental diesel fuel additives are not generally

recommended . This recommendation is due to

potential damage to the fuel system or the engine.

Your fuel supplier or the fuel manufacturer will add the

appropriate supplemental diesel fuel additives.

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70

SEBU8609

Maintenance Recommendations

System Pressure Release

Maintenance

Recommendations

Components for the driven equipment should also be

considered. When possible, remove the component

that requires welding. When welding on an engine

that is equipped with an ECM and removal of the

component is not possible, the following procedure

must be followed. This procedure minimizes the risk

to the electronic components.

i04056177

System Pressure Release

1. Stop the engine. Remove the electrical power from

the ECM.

Coolant System

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

off.

3. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is installed,

open the switch.

Pressurized system: Hot  coolant can cause seri-

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

diator is cool.  Then loosen cap  slowly to relieve

the pressure.

4. Disconnect all electronic components from the

wiring harnesses. Include the following

components:

Ensure that the power supply is isolated before any

service or repair is performed.

•   Electronic components for the driven equipment

To relieve the pressure from the coolant system, turn

off the engine. Allow the cooling system pressure cap

to cool. Remove the cooling system pressure cap

slowly in order to relieve pressure.

•   ECM

•   Sensors

•   Electronically controlled valves

•   Relays

Fuel System

To relieve the pressure from the fuel system, turn off

the engine.

•   Aftertreatment ID module

Engine Oil

NOTICE

To relieve pressure from the lubricating system, turn

off the engine.

Do not use electrical components (ECM or ECM sen-

sors)  or electronic  component grounding  points  for

grounding the welder.

i04055929

Welding on Engines with

Electronic Controls

Correct welding procedures are necessary in order to

avoid damage to the following components:

•   Electronic Control Module (ECM) on the engine

•   Clean Emissions Module (CEM)

•   Sensors

•   Associated components

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SEBU8609

71

Maintenance Recommendations

Severe Service Application

i04150276

Severe Service Application

Severe service is the application of an engine that

exceeds the current published standards for that

engine. Perkins  maintains standards for the

following engine parameters:

•   Performance such as power range, speed range,

and fuel consumption

•   Fuel quality

•   Operational Altitude

•   Maintenance intervals

•   Oil selection and maintenance

•   Coolant type and maintenance

•   Environmental qualities

•   Installation

•   The temperature of the fluid in the engine

Refer to the standards for the engine or consult your

Perkins &a, mp;n, bsp;dealer or your Perkins  distributor in order to

determine if the engine is operating within the defined

parameters.

Illustration 41

g01075639

Use the example above. The current flow from the

welder to the ground clamp of the welder will not

damage any associated components.

Severe service operation can accelerate component

wear. Engines that operate under severe conditions

may need more frequent maintenance intervals in

order to ensure maximum reliability and retention of

full service life.

(1) Engine

(2) Welding electrode

(3) Keyswitch in the OFF position

(4) Battery disconnect switch in the open position

(5) Disconnected battery cables

(6) Battery

(7) Electrical/Electronic component

(8) Minimum distance between the component that is being welded

and any electrical/electronic component

(9) The component that is being welded

(10) Current path of the welder

(11) Ground clamp for the welder

Due to individual applications, it is not possible to

identify all of the factors which can contribute to

severe service operation. Consult your Perkins

dealer or your Perkins  distributor for the unique

maintenance that is necessary for the engine.

The operating environment, incorrect operating

procedures, and incorrect maintenance procedures

can be factors which contribute to a severe service

application.

5. When possible, connect the ground clamp for the

welding equipment directly to the engine

component that will be welded. Place the clamp as

close as possible to the weld. Close positioning

reduces the risk of welding current damage to the

engine bearings, to the electrical components, and

to other components.

EnvironmentalFactors

Ambient temperatures – The engine may be

exposed to extended operation in cold environments

or hot environments. Valve components can be

damaged by carbon buildup if the engine is frequently

started and stopped in cold temperatures. Hot intake

air reduces engine performance.

6. Protect the wiring harnesses from welding debris

and/or from welding spatter.

7. Use standard welding procedures to weld the

materials together.

Quality of the air – The engine may be exposed to

extended operation in an environment that is dirty or

dusty, unless the equipment is cleaned regularly.

Mud, dirt, and dust can encase components.

Maintenance can be difficult. The buildup can contain

corrosive chemicals.

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SEBU8609

Maintenance Recommendations

Severe Service Application

Buildup – Compounds, elements, corrosive

chemicals, and salt can damage some components.

Altitude – Problems can arise when the engine is

operated at altitudes that are higher than the intended

settings for that application. Necessary adjustments

should be made.

Incorrect Operating Procedures

•   Extended operation at low idle

•   Frequent hot shutdowns

•   Operating at excessive loads

•   Operating at excessive speeds

•   Operating outside the intended application

Incorrect Maintenance Procedures

•   Extending the maintenance intervals

•   Failure to use recommended fuel, lubricants, and

coolant/antifreeze

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73

Maintenance Recommendations

Maintenance Interval Schedule

i05146189

“Belts - Inspect/Replace”.........................................77

“Crankcase Breather (Canister) - Replace”.............83

“Engine Valve Lash - Check”...................................89

“Turbocharger - Inspect”..........................................96

MaintenanceInterval Schedule

When Required

Every 2000 Service Hours

“Battery - Replace”...................................................75

“Battery or Battery Cable - Disconnect”...................76

“Engine - Clean”.......................................................85

“Fuel System - Prime”..............................................92

“Alternator - Inspect”................................................73

“Engine Mounts - Inspect” .......................................86

“Starting Motor - Inspect”.........................................96

Every 3000 Service Hours

Daily

“Coolant Temperature Regulator - Replace” ...........82

“Diesel Particulate Filter - Clean”.............................84

“Fuel Injector - Test/Change”...................................91

“Glow Plugs (ARD Combustion) - Replace”............93

“Radiator Pressure Cap - Clean/Replace”...............96

“Water Pump - Inspect”............................................98

“Coolant Level - Check”...........................................80

“Engine Air Cleaner Service Indicator - Inspect”.....85

“Engine Air Precleaner - Check/Clean”...................86

“Engine Oil Level - Check”.......................................86

“Walk-Around Inspection”........................................97

Every 50 Service Hours or Weekly

Every 3000 Service Hours or 2

Years

“Fuel Tank Water and Sediment - Drain”.................93

Every 250 Service Hours or 6

Months

“Coolant (Commercial Heavy-Duty) - Change” .......77

Every 12 000 Service Hours or 6

Years

“Alternator and Fan Belts - Inspect/Adjust” .............74

“Belts - Inspect/Adjust/Replace”..............................76

“Coolant (ELC) - Change”........................................79

Every 500 Service Hours

Commissioning

“Engine Air Cleaner Element - Replace” .................85

“Fan Clearance - Check” .........................................90

“Fuel Filter (In-Line) - Replace”................................90

“Fuel System Secondary Filter - Replace” ..............92

“Fan Clearance - Check” .........................................90

i02322311

Alternator - Inspect

Every 500 Service Hours or 1 Year

Perkins  recommends a scheduled inspection of the

alternator. Inspect the alternator for loose

connections and correct battery charging. Check the

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.

“Battery Electrolyte Level - Check”..........................75

“Cooling System Supplemental Coolant Additive

(SCA) - Test/Add”.....................................................82

“Engine Oil and Filter - Change”..............................87

“Hoses and Clamps - Inspect/Replace”...................94

“Radiator - Clean” ....................................................95

Every 1000 Service Hours

“Alternator and Fan Belts - Replace”.......................75

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SEBU8609

Maintenance Recommendations

Alternator and Fan Belts - Inspect/Adjust

Check the alternator and the battery charger for

correct operation. If the batteries are correctly

charged, the ammeter reading should be very near

zero. All batteries should be kept charged. The

batteries should be kept warm because temperature

affects the cranking power. If the battery is too cold,

the battery will not crank the engine. When the engine

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

run for short periods, the batteries may not fully

charge. A battery with a low charge will freeze more

easily than a battery with a full charge.

Install the gauge (1) at the center of the belt between

the alternator and the crankshaft pulley and check the

belt tension. The correct tension for a new belt is

400 N (90 lb) to 489 N (110 lb). The correct tension

for a used belt that has been in operation for 30

minutes or more at the rated speed is 267 N  (60 lb) to

356 N (80 lb).

Adjustment

i05162309

Alternator and Fan Belts -

Inspect/Adjust

Inspection

To maximize the engine performance, inspect the belt

for wear and for cracking. Replace a belt that is worn

or damaged.

If a belt is too loose, vibration causes unnecessary

wear on the belt and pulleys. Loose belts may slip

enough to cause overheating.

To accurately check the belt tension, a suitable gauge

should be used.

Illustration 43

g03316634

1. Loosen bolts (1) and adjusting bolt (2). Loosen bolt

(4).

2. Move the alternator (3) in order to increase or

decrease the belt tension.

3. Tighten adjusting bolt (2). Tighten bolts (1) and

tighten bolt (4). Refer to the Specifications Manual

for the correct torque settings.

Illustration 42

g03316638

Typical example

(1) Burroughs Gauge

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SEBU8609

75

Maintenance Recommendations

Alternator and Fan Belts - Replace

i05162326

Alternator and Fan Belts -

Replace

The battery cables or the  batteries should not be

removed with the battery cover in place. The bat-

tery cover should be  removed before any servic-

ing is attempted.

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion

resulting in personal injury.

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

electrical loads.

2. Turn off any battery chargers. Disconnect any

battery chargers.

3. The NEGATIVE “-”  cable connects the NEGATIVE

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

on the starting motor. Disconnect the cable from

the NEGATIVE “-”  battery terminal.

4. The POSITIVE “+”  cable connects the POSITIVE

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

on the starting motor. Disconnect the cable from

the POSITIVE “+”  battery terminal.

Note: Always recycle a battery. Never discard a

battery. Dispose of used batteries to an appropriate

recycling facility.

Illustration 44

g03316634

(1) Securing bolt

(2) Adjusting bolt

(3) Alternator

5. Remove the used battery.

(4) Lower securing bolt

6. Install the new battery.

The air pump belt must be removed before the fan

belt can be removed.

Note: Before the cables are connected, ensure that

the engine start switch is OFF.

7. Connect the cable from the starting motor to the

POSITIVE  “+” battery terminal.

Refer to the Disassembly and Assembly Manual for

the installation procedure and the removal procedure

for both belts.

i02322315

8. Connect the NEGATIVE “-”  cable to the

NEGATIVE  “-” battery terminal.

Battery - Replace

i02747977

Battery Electrolyte Level -

Check

Batteries give  off combustible  gases  which can

explode.  A   spark  can  cause   the  combustible

gases to ignite. This can result in severe personal

injury or death.

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

when the engine is run for short periods, the batteries

may not fully recharge. Ensure a full charge in order

to help prevent the battery from freezing. If batteries

are correctly charged, the ammeter reading should be

very near zero, when the engine is in operation.

Ensure proper ventilation for batteries that are in

an enclosure. Follow the proper procedures in or-

der to  help prevent electrical arcs  and/or sparks

near batteries. Do  not smoke when  batteries are

serviced.

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SEBU8609

Maintenance Recommendations

Battery or Battery Cable - Disconnect

4. Clean all disconnected connection and battery

terminals.

All lead-acid batteries contain sulfuric acid which

can  burn the  skin and  clothing.  Always wear  a

face shield and protective clothing when working

on or near batteries.

5. Use a fine grade of sandpaper to clean the

terminals and the cable clamps. Clean the items

until the surfaces are bright or shiny. DO NOT

remove material excessively. Excessive removal of

material can cause the clamps to not fit correctly.

Coat the clamps and the terminals with a suitable

silicone lubricant or petroleum jelly.

1. Remove the filler caps. Maintain the electrolyte

level to the “FULL”  mark on the battery.

If the addition of water is necessary, use distilled

water. If distilled water is not available use clean

water that is low in minerals. Do not use artificially

softened water.

6. Tape the cable connections in order to help prevent

accidental starting.

2. Check the condition of the electrolyte with a

7. Proceed with necessary system repairs.

suitable battery tester.

8. In order to connect the battery, connect the positive

3. Install the caps.

connection before the negative connector.

4. Keep the batteries clean.

i05162380

Clean the battery case with one of the following

cleaning solutions:

Belts - Inspect/Adjust/Replace

(Air Pump Belt)

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

and 1 L (1 qt) of clean water.

•   Use a solution of ammonium hydroxide .

Inspection

Thoroughly rinse the battery case with clean water.

To maximize the engine performance, inspect the belt

for wear and for cracking. Replace a belt that is worn

or damaged.

i02323088

Battery or Battery Cable -

Disconnect

If the belt is too loose, vibration causes unnecessary

wear on the belt and pulleys. A loose belt may slip

enough to cause overheating.

The battery cables or the batteries  should not be

removed with the battery cover in place. The bat-

tery cover should be  removed before any servic-

ing is attempted.

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion

resulting in personal injury.

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

ignition switch (if equipped) to the OFF position

and remove the key and all electrical loads.

2. Disconnect the negative battery terminal. Ensure

that the cable cannot contact the terminal. When

four 12 volt batteries are involved, two negative

connection must be disconnected.

3. Remove the positive connection.

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77

Maintenance Recommendations

Belts - Inspect/Replace

Adjust

Replace Belt

The belt should only be replaced if the belt is worn or

damaged.

i05162435

Belts - Inspect/Replace

(Air Pump belt)

The air pump belt must be replaced at 1000 hours.

Refer to Disassembly and Assembly, “Belt (Air Pump)

- Remove and Install” for more information.

i05160093

Coolant (Commercial Heavy-

Duty) - Change

Illustration 45

g03316723

NOTICE

Care  must be  taken to  ensure  that fluids  are  con-

tained  during   performance  of  inspection,   mainte-

nance, testing, adjusting and repair of the product. Be

prepared to  collect the fluid  with suitable containers

before  opening any  compartment  or disassembling

any component containing fluids.

Dispose  of all  fluids according  to Local  regulations

and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may  cause rapid wear and  shortened

component life.

Clean the cooling system and flush the cooling

system before the recommended maintenance

interval if the following conditions exist:

•   The engine overheats frequently.

•   Foaming is observed.

Illustration 46

g03316722

The correct tension for a new belt is 310 N  (69 lb).

The correct tension for a used belt that has been in

operation for 30 minutes or more at the rated speed is

220 N (49 lb).

•   The oil has entered the cooling system and the

coolant is contaminated.

•   The fuel has entered the cooling system and the

coolant is contaminated.

The belt tension should be checked at the center

point of the belt between the pulleys.

Note: When the cooling system is cleaned, only

clean water is needed.

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

2. Adjust bolt (2) in order to tension the belt.

3. Tighten bolt (1) and bolt (3) securely.

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78

SEBU8609

Maintenance Recommendations

Coolant (Commercial Heavy-Duty) - Change

Note: Inspect the water pump and the water

temperature regulator after the cooling system has

been drained. This inspection is a good opportunity to

replace the water pump, the water temperature

regulator, and the hoses, if necessary.

For information regarding the disposal and the

recycling of used coolant, consult your Perkins

dealer or your Perkins  distributor.

Flush

Drain

1. Flush the cooling system with clean water in order

to remove any debris.

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

engine. Close the drain cock or install the drain

plug on the radiator.

Pressurized System: Hot coolant can  cause seri-

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure   cap  slowly   in  order   to   relieve  the

pressure.

NOTICE

Do not fill the cooling system faster than 5 L

(1.3 US gal) per minute to avoid air locks.

Cooling   system  air   locks  may   result   in  engine

damage.

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

Loosen the cooling system filler cap slowly in order

to relieve any pressure. Remove the cooling

system filler cap.

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

cooling system filler cap.

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

temperature reaches 49 to 66 °C  (120 to 150 °F).

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

Loosen the cooling system filler cap slowly in order

to relieve any pressure. Remove the cooling

system filler cap. Open the drain cock or remove

the drain plug on the engine. Open the drain cock

or remove the drain plug on the radiator. Allow the

water to drain. Flush the cooling system with clean

water.

Fill

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

engine. Close the drain cock or install the drain

plug on the radiator.

NOTICE

Do not fill the cooling system faster than 5 L

(1.3 US gal) per minute to avoid air locks.

Illustration 47

g03305397

Typical example

Cooling   system  air   locks  may   result   in  engine

damage.

2. Open the drain cock or remove the drain plug (1)

on the engine. Open the drain cock or remove the

drain plug on the radiator.

2. Fill the cooling system with Commercial Heavy-

Duty Coolant. Add Supplemental Coolant Additive

to the coolant. For the correct amount, refer to the

Operation and Maintenance Manual, “Fluid

Recommendations” topic (Maintenance Section)

for more information on cooling system

specifications. Do not install the cooling system

filler cap.

Allow the coolant to drain.

NOTICE

Dispose of  used engine  coolant or  recycle. Various

methods have been proposed to reclaim used coolant

for reuse in  engine cooling systems. The full  distilla-

tion procedure is the only method acceptable by Per-

kins to reclaim the coolant.

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SEBU8609

79

Maintenance Recommendations

Coolant (ELC) - Change

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

engine rpm to high idle. Run the engine at high idle

for 1 minute in order to purge the air from the

cavities of the engine block. Stop the engine.

•   The engine overheats frequently.

•   Foaming is observed.

•   The oil has entered the cooling system and the

coolant is contaminated.

4. Check the coolant level. Maintain the coolant level

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

pipe for filling. Maintain the coolant level in the

expansion bottle (if equipped) at the correct level.

•   The fuel has entered the cooling system and the

coolant is contaminated.

Note: When the cooling system is cleaned, only

clean water is needed when the Extended Life

Coolant (ELC) is drained and replaced.

5. Clean the cooling system filler cap. Inspect the

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

gasket that is on the cooling system filler cap is

damaged, discard the old cooling system filler cap

and install a new cooling system filler cap. If the

gasket that is on the cooling system filler cap is not

damaged, use a suitable pressurizing pump in

order to pressure test the cooling system filler cap.

The correct pressure for the cooling system filler

cap is stamped on the face of the cooling system

filler cap. If the cooling system filler cap does not

retain the correct pressure, install a new cooling

system filler cap.

Note: Inspect the water pump and the water

temperature regulator after the cooling system has

been drained. This inspection is a good opportunity to

replace the water pump, the water temperature

regulator, and the hoses, if necessary.

Drain

Pressurized System: Hot coolant can  cause seri-

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure   cap  slowly   in  order   to   relieve  the

pressure.

6. Start the engine. Inspect the cooling system for

leaks and for correct operating temperature.

i05149269

Coolant (ELC) - Change

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

Loosen the cooling system filler cap slowly in order

to relieve any pressure. Remove the cooling

system filler cap.

NOTICE

Care  must be  taken to  ensure  that fluids  are  con-

tained  during   performance  of  inspection,   mainte-

nance, testing, adjusting and repair of the product. Be

prepared to  collect the fluid  with suitable containers

before  opening any  compartment  or disassembling

any component containing fluids.

Dispose of  all  fluids according  to  Local regulations

and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

Clean the cooling system and flush the cooling

system before the recommended maintenance

interval if the following conditions exist:

Illustration 48

g03305397

Typical example

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80

SEBU8609

Maintenance Recommendations

Coolant Level - Check

2. Open the drain cock or remove the drain plug (1)

on the engine. Open the drain cock or remove the

drain plug on the radiator.

NOTICE

Do not fill the cooling system faster than 5 L

(1.3 US gal) per minute to avoid air locks.

Allow the coolant to drain.

Cooling   system  air   locks  may   result   in  engine

damage.

NOTICE

Dispose of  used engine  coolant or  recycle. Various

methods have been proposed to reclaim used coolant

for reuse in  engine cooling systems. The full  distilla-

tion procedure is the only method acceptable by Per-

kins to reclaim the coolant.

2. Fill the cooling system with ELC. Refer to the

Operation and Maintenance Manual, “Fluid

Recommendations” topic (Maintenance Section)

for more information on cooling system

specifications. Do not install the cooling system

filler cap.

For information regarding the disposal and the

recycling of used coolant, consult your Perkins

dealer or your Perkins  distributor.

3. Start and operate the engine at low idle. Increase

the engine rpm to high idle. Operate the engine at

high idle for 1 minute in order to purge the air from

the cavities of the engine block. Stop the engine.

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

4. Check the coolant level. Maintain the coolant level

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

pipe for filling. Maintain the coolant level in the

expansion bottle (if equipped) at the correct level.

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

engine. Close the drain cock or install the drain

plug on the radiator.

5. Clean the cooling system filler cap. Inspect the

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

gasket that is on the cooling system filler cap is

damaged, discard the old cooling system filler cap

and install a new cooling system filler cap. If the

gasket that is on the cooling system filler cap is not

damaged, use a suitable pressurizing pump in

order to pressure test the cooling system filler cap.

The correct pressure for the cooling system filler

cap is stamped on the face of the cooling system

filler cap. If the cooling system filler cap does not

retain the correct pressure, install a new cooling

system filler cap.

NOTICE

Do not fill the cooling system faster than 5 L

(1.3 US gal) per minute to avoid air locks.

Cooling   system  air   locks  may   result   in  engine

damage.

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

cooling system filler cap.

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

temperature reaches 49 to 66 °C (120 to 150 °F).

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

Loosen the cooling system filler cap slowly in order

to relieve any pressure. Remove the cooling

system filler cap. Open the drain cock or remove

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.

6. Start the engine. Inspect the cooling system for

leaks and for correct operating temperature.

i05149389

Coolant Level - Check

Engines With a Coolant Recovery

Tank

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.

Note: The cooling system may not have been

provided by Perkins . The procedure that follows 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.

This document is printed from SPI². Not for RESALE

 

SEBU8609

81

Maintenance Recommendations

Coolant Level - Check

4. Clean the filler cap and the receptacle. Reinstall

the filler cap and inspect the cooling system for

leaks.

NOTICE

When any  servicing or  repair of  the engine  cooling

system  is  performed, the  procedure  must  be  per-

formed with the engine on level ground. Level ground

will allow  you to  check accurately the  coolant level.

This checking will also help in avoiding the risk  of in-

troducing an air lock into the coolant system.

Note: The coolant will expand as the coolant heats

up during normal engine operation. The additional

volume will be forced into the coolant recovery tank

during engine operation. When the engine is stopped

and cool, the coolant will return to the engine.

1. Observe the coolant level in the coolant recovery

tank. Maintain the coolant level to “COLD FULL”

mark on the coolant recovery tank.

Engines Without a Coolant

Recovery Tank

Check the coolant level when the engine is stopped

and cool.

Pressurized System: Hot coolant can  cause seri-

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure   cap  slowly   in  order   to   relieve  the

pressure.

2. Loosen filler cap slowly in order to relieve any

pressure. Remove the filler cap.

3. Pour the correct coolant mixture into the tank.

Refer to the Operation and Maintenance Manual,

“Refill Capacities and Recommendations” for

information on the correct mixture and type of

coolant. Refer to the Operation and Maintenance

Manual, “Refill Capacities and Recommendations”

for the engine cooling system capacity. Do not fill

the coolant recovery tank above “COLD FULL”

mark.

Illustration 50

g00285520

Cooling system filler cap

Pressurized System: Hot coolant can  cause seri-

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure   cap  slowly   in  order   to   relieve  the

pressure.

1. Remove the cooling system filler cap slowly in

order to relieve pressure.

2. Maintain the coolant level at the maximum mark

that is correct for your application. If the engine is

equipped with a sight glass, maintain the coolant

level to the correct level in the sight glass.

3. Clean the cooling system filler cap and inspect the

gasket. If the gasket is damaged, discard the old

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

not damaged, use a suitable pressurizing pump in

order to pressure test the filler cap. The correct

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

the filler cap does not retain the correct pressure,

install a new filler cap.

Illustration 49

g02590196

Filler cap

This document is printed from SPI². Not for RESALE

 

82

SEBU8609

Maintenance Recommendations

Coolant Temperature Regulator - Replace

4. Inspect the cooling system for leaks.

i03644948

Cooling System Supplemental

Coolant Additive (SCA) - Test/

Add

i05160120

Coolant Temperature

Regulator - Replace

Replace the water temperature regulator before the

water temperature regulator fails. This is a

recommended preventive maintenance practice.

Replacing the water temperature regulator reduces

the chances for unscheduled downtime.

Cooling system  coolant additive  contains alkali.

To  help  prevent  personal  injury,  avoid  contact

with the skin  and the eyes. Do  not drink cooling

system coolant additive.

A water temperature regulator that fails in a partially

opened position can cause overheating or

overcooling of the engine.

Test for SCA Concentration

A water temperature regulator that fails in the closed

position can cause excessive overheating. Excessive

overheating could result in cracking of the cylinder

head or piston seizure problems.

Heavy-Duty Coolant/Antifreezeand SCA

NOTICE

Do not exceed the recommended six percent supple-

mental coolant additive concentration.

A water temperature regulator that fails in the open

position will cause the engine operating temperature

to be too low during partial load operation. Low

engine operating temperatures during partial loads

could cause an excessive carbon buildup inside the

cylinders. This excessive carbon buildup could result

in an accelerated wear of the piston rings and wear of

the cylinder liner.

Use a Coolant Conditioner Test Kit in order to check

the concentration of the SCA.

Add the SCA, If Necessary

NOTICE

NOTICE

Failure to  replace your  water temperature  regulator

on a  regularly scheduled  basis could  cause severe

engine damage.

Do not exceed the  recommended amount of supple-

mental coolant additive concentration. Excessive sup-

plemental  coolant  additive  concentration  can  form

deposits on  the  higher temperature surfaces  of the

cooling system,  reducing the  engine's heat  transfer

characteristics.  Reduced heat  transfer  could cause

cracking of the cylinder head and other high tempera-

ture  components.  Excessive  supplemental  coolant

additive  concentration could  also  result  in  radiator

tube blockage, overheating, and/or accelerated water

pump seal wear. Never use  both liquid supplemental

coolant additive and the spin-on element (if equipped)

at the same time. The use of those additives together

could result in supplemental coolant additive concen-

tration exceeding the recommended maximum.

Perkins

engines incorporate a shunt design cooling

system and require operating the engine with a water

temperature regulator installed.

If the  water temperature regulator  is installed  incor-

rectly,  the  engine  may  overheat,  causing  cylinder

head damage.  Ensure that  the new water  tempera-

ture regulator is installed  in the original position. En-

sure that the water temperature regulator vent hole is

open.

Do not use liquid gasket material on the gasket or cyl-

inder head surface.

Refer to the Disassembly and Assembly Manual,

“Water Temperature Regulator - Remove and Install”

for the replacement procedure of the water

temperature regulator, or consult your Perkins

dealer or your Perkins  distributor.

Pressurized System: Hot coolant can  cause seri-

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure   cap  slowly   in  order   to   relieve  the

pressure.

Note: If only the water temperature regulators are

replaced, drain the coolant from the cooling system to

a level that is below the water temperature regulator

housing.

This document is printed from SPI². Not for RESALE

 

SEBU8609

83

Maintenance Recommendations

Crankcase Breather (Canister) - Replace

•   The filter element within the crankcase breather

must be serviced at the prescribed service interval.

NOTICE

When any  servicing or  repair of  the engine  cooling

system  is  performed  the  procedure  must  be  per-

formed with the engine on level ground. This will allow

you to accurately check the coolant level. This will al-

so help in avoiding  the risk of introducing an air lock

into the coolant system.

•   The correct filter element must be installed before

the engine is operated.

•   The installation of the filter element is very

important.

•   The quality of the filter element that is installed is

very important.

1. Slowly loosen the cooling system filler cap in order

to relieve the pressure. Remove the cooling

system filler cap.

•   The filter element protects the engine from

excessive quantities of oil from entering the

induction system. The filter element also protects

the engine aftertreatment system.

Note: Always discard drained fluids according to local

regulations.

2. If necessary, drain some coolant from the cooling

system into a suitable container in order to allow

space for the extra SCA.

Note: Excessive quantities of oil that enter the

induction system of the engine can rapidly increase

the engine speed without control.

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

Operation and Maintenance Manual, “Refill

Capacities and Recommendations” for more

information on SCA requirements.

4. Clean the cooling system filler cap and inspect the

gasket. If the gasket is damaged, discard the old

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

not damaged, use a suitable pressurizing pump in

order to pressure test the filler cap. The correct

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

the filler cap does not retain the correct pressure,

install a new filler cap.

i05199993

Crankcase Breather (Canister)

- Replace

Illustration 51

g03331718

Typical example

1. Ensure that dirt cannot enter the breather

Hot oil  and hot components can  cause personal

injury. Do not allow  hot oil or hot components to

contact the skin.

assembly. Ensure that the outside body of the

breather assembly is clean and free from damage.

Place a container under the breather assembly.

2. Remove clip (3) and remove hose (4) from cap (2).

Remove cap (2) from the main body (1).

NOTICE

Ensure that the engine is stopped  before any servic-

ing or repair is performed.

The crankcase breather is a very important

component in order to keep your engine emissions

compliant.

This document is printed from SPI². Not for RESALE

 

84

,

S, EBU8609

Maintenance Recommendations

Diesel Particulate Filter - Clean

i05153374

Diesel Particulate Filter - Clean

Wear goggles, gloves,  protective clothing, and a

National  Institute  for  Occupational   Safety  and

Health (NIOSH) approved P95 or N95 half-face res-

pirator when  handling a  used  Diesel Particulate

Filter or Catalytic Converter Muffler. Failure to do

so could result in personal injury.

The muffler, catalytic converter/muffler, and diesel

particulate filter will become extremely hot during

engine operation. A hot muffler, catalytic convert-

er/muffler and  diesel particulate  filter can cause

serious burns.  Allow  adequate cooling  time be-

fore working on or near the muffler, catalytic con-

verter/muffler and diesel particulate filter.

Illustration 52

g03331704

Typical example

3. Remove filter element (5) and remove O ring seal

(6) and discard.

Note: Ensure that all parts are clean and free from

dirt.

4. Install a new O ring seal (6) onto the cap (2) and

install a new filter element (5) into the cap (2).

5. Install cap assembly into the main body (1).

Tighten the cap assembly to 10 N·m  (7 lb ft).

6. Install hose (4) and clip (3). Remove the container

and clean away any split fluid.

Illustration 53

g02335296

Typical example

Note: Improper cleaning or repair of the Diesel

Particulate Filter (DPF) can damage the DPF and the

engine aftertreatment system. Contact your Perkins

dealer for more information.

The DPF is enclosed within the assembly (1). For

information on removal of the DPF, refer to

Disassembly and Assembly, “DPF - Remove”.

This document is printed from SPI². Not for RESALE

 

SEBU8609

85

Maintenance Recommendations

Engine - Clean

•   The DPF on the three cylinder engine is different

from the four cylinder engine.

Aftertreatment

During the engine cleaning process, ensure that

water or cleaning fluids cannot enter the

aftertreatment system. If cleaning fluids enters the

aftertreatment system, damage could occur.

•   Only ultra low sulfur diesel fuel can be used in an

application that has an aftertreatment regeneration

device. The use of other fuel will damage your

engine system.

i05160996

•   The engine must be operated on CJ-4

specification of engine oil.

Engine Air Cleaner Element -

Replace

i03991933

Engine - Clean

The air cleaner may be installed by the Original

Equipment Manufacture (OEM). Refer to the OEM for

instruction on how to remove the element within the

air cleaner.

i02335405

Personal  injury  or  death  can  result  from  high

voltage.

Engine Air Cleaner Service

Indicator - Inspect

Moisture

can

create

paths

of

electrical

conductivity.

Make sure that the electrical system is OFF. Lock

out the starting controls and tag the controls “DO

NOT OPERATE”  .

Some engines may be equipped with a different

service indicator.

Some engines are equipped with a differential gauge

for inlet air pressure. The differential gauge for inlet

air pressure displays the difference in the pressure

that is measured before the air cleaner element and

the pressure that is measured after the air cleaner

element. As the air cleaner element becomes dirty,

the pressure differential rises. If your engine is

equipped with a different type of service indicator,

follow the OEM recommendations in order to service

the air cleaner service indicator.

NOTICE

Accumulated grease  and oil  on  an engine  is a  fire

hazard. Keep the  engine clean. Remove  debris and

fluid spills  whenever  a significant  quantity accumu-

lates on the engine.

Periodic cleaning of the engine is recommended.

Steam cleaning the engine will remove accumulated

oil and grease. A clean engine provides the following

benefits:

The service indicator may be mounted on the air

cleaner element or in a remote location.

•   Easy detection of fluid leaks

•   Maximum heat transfer characteristics

•   Ease of maintenance

Note: Caution must be used in order to prevent

electrical components from being damaged by

excessive water when the engine is cleaned.

Pressure washers and steam cleaners should not be

directed at any electrical connectors or the junction of

cables into the rear of the connectors. Avoid electrical

components such as the alternator, the starter, and

the ECM. Protect the fuel injection pump from fluids in

order to wash the engine.

Illustration 54

g00103777

Typical service indicator

This document is printed from SPI². Not for RESALE

 

86

SEBU8609

Maintenance Recommendations

Engine Air Precleaner - Check/Clean

Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner element

should be replaced when one of the following

conditions occur:

Note: When the engine is operated in dusty

applications, more frequent cleaning is required.

i02323089

•   The yellow diaphragm enters the red zone.

•   The red piston locks in the visible position.

Engine Mounts - Inspect

Test the Service Indicator

Note: The engine mounts may not have been

supplied by Perkins . Refer to the OEM information

for further information on the engine mounts and the

correct bolt torque.

Service indicators are important instruments.

•   Check for ease of resetting. The service indicator

should reset in less than three pushes.

Inspect the engine mounts for deterioration and for

correct bolt torque. Engine vibration can be caused

by the following conditions:

•   Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.

The yellow core should latch at the greatest

vacuum that is attained.

•   Incorrect mounting of the engine

•   Deterioration of the engine mounts

•   Loose engine mounts

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

indicator may be restricted.

Any engine mount that shows deterioration should be

replaced. Refer to the OEM information for the

recommended torques.

The service indicator may need to be replaced

frequently in environments that are severely dusty.

i05164949

i02927289

Engine Oil Level - Check

Engine Air Precleaner - Check/

Clean

Hot oil  and hot components can  cause personal

injury. Do not allow  hot oil or hot components to

contact the skin.

Illustration 55

g01453058

Typical engine air precleaner

(1) Wing nut

(2) Cover

(3) Body

Remove wing nut (1) and cover (2). Check for an

accumulation of dirt and debris in body (3). Clean the

body, if necessary.

After cleaning the precleaner, install cover (2) and

wing nut (1).

This document is printed from SPI². Not for RESALE

 

SEBU8609

87

Maintenance Recommendations

Engine Oil and Filter - Change

i05153469

Engine Oil and Filter - Change

Hot oil  and hot components can  cause personal

injury. Do not allow  hot oil or hot components to

contact the skin.

NOTICE

Care  must be  taken to  ensure  that fluids  are  con-

tained  during   performance  of  inspection,   mainte-

nance, testing, adjusting and repair of the product. Be

prepared to  collect the fluid  with suitable containers

before  opening any  compartment  or disassembling

any component containing fluids.

Dispose of all fluids according to local regulations and

mandates.

Illustration 56

g03317856

(Y) “ADD” mark. (X) “FULL”   mark.

(A) Original oil level gauge

(B) Alternative oil level gauge

NOTICE

Keep all parts clean from contaminants.

NOTICE

Perform this maintenance with the engine stopped.

Contaminants may  cause rapid wear and  shortened

component life.

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

with the draining cold oil. Drain the crankcase with the

engine stopped. Drain the crankcase with the oil

warm. This draining method allows the waste

particles that are suspended in the oil to be drained

correctly.

Note: Oil gauge (A) or oil gauge (B) may be installed

in the engine.

1. Maintain the oil level between “ADD” mark (Y) and

“FULL” mark (X) on oil level gauge (1). Do not fill

the crankcase above “FULL”  mark (X).

NOTICE

Failure to follow this recommended procedure will

cause the waste particles to be recirculated through

the engine lubrication system with the new oil.

Operating your engine when the oil level is above the

“FULL”  mark could cause your crankshaft to dip into

the oil.  The air bubbles  created from the  crankshaft

dipping into the oil  reduces the oil's lubricating char-

acteristics and could result in the loss of power.

Drain the Engine Oil

After the engine has been run at the normal operating

temperature, stop the engine. Use one of the

following methods to drain the engine crankcase oil:

2. Remove the oil filler cap and add oil, if necessary.

Clean the oil filler cap. Install the oil filler cap.

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

the drain valve knob counterclockwise in order to

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

drain valve knob clockwise in order to close the

drain valve.

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

remove the oil drain plug in order to allow the oil to

drain. After the oil has drained, the oil drain plug

should be cleaned and installed.

This document is printed from SPI². Not for RESALE

 

88

SEBU8609

Maintenance Recommendations

Engine Oil and Filter - Change

Replace the Oil Filter

NOTICE

Perkins   oil filters are built to Perkins  specifications.

Use  of  an  oil  filter  not  recommended  by  Perkins

could result in  severe engine damage  to the engine

bearings, crankshaft,  etc.,  as a  result  of the  larger

waste particles from unfiltered oil entering the engine

lubricating system. Only use  oil filters recommended

by Perkins .

1. Remove the oil filter with a suitable tool.

Note: The following actions can be carried out as part

of the preventive maintenance program.

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

apart the pleats and inspect the oil filter for metal

debris. An excessive amount of metal debris in the

oil filter may indicate early wear or a pending

failure.

Illustration 57

g01334593

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

wear on the steel and cast iron parts of the engine.

(1) Oil cooler

(2) Adapter

(3) Oil filter

Note: The oil cooler (1) and the adapter (2) are

installed on engines that have a turbocharger.

3. Clean the sealing surface of the cylinder block or

the oil cooler (1).

Nonferrous metals may indicate wear on the

aluminum parts, brass parts, or bronze parts of the

engine. Parts that may be affected include the

following items: main bearings, rod bearings,

turbocharger bearings and cylinder heads.

4. Apply clean engine oil to the new oil filter seal (3).

Due to normal wear and friction, it is not

uncommon to find small amounts of debris in the

oil filter. Consult your Perkins  dealer or your

Perkins  distributor in order to arrange for a further

analysis if an excessive amount of debris is found

in the oil filter.

NOTICE

Do not fill the oil filters with oil before installing  them.

This oil  would not be  filtered and could  be contami-

nated. Contaminated oil can cause accelerated wear

to engine components.

5. Install the oil filter. Tighten the oil filter by hand. Do

not overtighten the oil filter.

Fill the Engine Crankcase

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

and Maintenance Manual for more information on

lubricant specifications. Fill the crankcase with the

correct amount of oil. Refer to the Operation and

Maintenance Manual for more information on refill

capacities.

NOTICE

If equipped with  an auxiliary oil filter system  or a re-

mote oil filter system,  follow the OEM or filter  manu-

facturer's recommendations. Under filling or overfilling

the crankcase with oil can cause engine damage.

This document is printed from SPI². Not for RESALE

 

SEBU8609

89

Maintenance Recommendations

Engine Valve Lash - Check

NOTICE

NOTICE

To prevent crankshaft bearing damage, crank the en-

gine with the fuel OFF. This will fill the oil filters before

starting the engine. Do not crank the engine for more

than 30 seconds.

Only qualified service  personnel should perform this

maintenance. Refer to the Service Manual or your au-

thorized Perkins   dealer or  your Perkins

distributor

for the complete valve lash adjustment procedure.

Operation of  Perkins    engines  with incorrect  valve

lash can  reduce engine  efficiency, and  also reduce

engine component life.

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

for 2 minutes. Perform this procedure in order to

ensure that the lubrication system has oil and that

the oil filters are filled. Inspect the oil filter for oil

leaks.

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

the sump for a minimum of 10 minutes.

Ensure that  the engine can  not be  started while

this maintenance is being performed. To help pre-

vent possible injury, do not use the starting motor

to turn the flywheel.

Hot engine  components can cause  burns. Allow

additional time for the engine to cool before meas-

uring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuring

the valve lash. The engine valve lash can be

inspected and adjusted when the temperature of the

engine is hot or cold.

Refer to Systems Operation, Testing and Adjusting,

“Engine Valve Lash - Inspect/Adjust” for more

information.

Illustration 58

g03306420

(Y) “ADD” mark. (X) “FULL”   mark.

(A) Original oil level gauge

(B) Alternative oil level gauge

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

level. Maintain the oil level between the  “MIN”  and

“MAX”  marks on the oil level gauge.

i05153520

Engine Valve Lash - Check

This maintenance is recommended by Perkins as

part of a lubrication and preventive maintenance

schedule in order to help provide maximum engine

life. The maintenance for the valve lash is important in

order to keep the engine compliant.

This document is printed from SPI². Not for RESALE

 

90

SEBU8609

Maintenance Recommendations

Fan Clearance - Check

i05153591

i05161054

Fan Clearance - Check

Fuel Filter (In-Line)- Replace

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent

possible  injury,  turn  the  start  switch  off when

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

Note: Refer to Systems Operation, Testing, and

Adjusting, “Cleanliness of Fuel System

Components” for detailed information on the

standards of cleanliness that must be observed

during ALL work on the fuel system.

NOTICE

Ensure that the engine is stopped  before any servic-

ing or repair is performed.

The location of the in-line fuel filter will depend on the

application that the engine has been installed.

Illustration 59

g03309719

Typical example

Ensure that the engine is stopped. Ensure that the

battery disconnect switch is in the OFF position.

Ensure that the cooling system is full.

The clearance between the cover (2) and the fan (1)

will require checking. The gap between the edge of

the cover and the tip of the fan blade (A) must be

checked in four equally spaced positions.

•   (A) equals 5 mm (0.19685 inch) for the three

cylinder engine and the four cylinder naturally

aspirated engine.

•   (A) equals 10 mm (0.39370 inch) for the

turbocharged engine.

Illustration 60

g03315616

Arrows show fuel flow

Note: The cover is not adjustable.

Note: The in-line fuel filter is an off engine part.

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

position. Remove clamp (3) and remove clamp (6).

2. Remove inlet hose (4) and remove outlet hose (5)

from in-line filter (1).

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91

Maintenance Recommendations

Fuel Injector - Test/Change

3. If installed, remove clamp (2) and remove in-line

filter (1) from application.

•   The engine will not start or the engine is difficult to

start.

•   Not enough power

4. Install new in-line filter (1) and install clamp (2).

•   The engine misfires or the engine runs erratically.

•   High fuel consumption

5. Install inlet hose (4) and install clamp (3). Install

outlet hose (5) and install clamp (6).

6. Turn the fuel supply valve (if equipped) to the ON

position. Prime the system, refer to this Operation

and Maintenance Manual, “Fuel System - Prime”.

•   Black exhaust smoke

•   The engine knocks or there is vibration in the

engine.

i02154268

•   Excessive engine temperature

Fuel Injector - Test/Change

For further information on the removal and the

installation of the fuel injectors, refer to the

Disassembly and Assembly manual.

For further information on the testing of fuel injectors,

refer to the Testing and Adjusting manual.

Identificationof a suspect Fuel

Injector

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.

Work carefully around an  engine that is running.

Engine parts that  are hot, or  parts that are mov-

ing, can cause personal injury.

Make  sure  that  you wear  eye  protection  at  all

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

skin and cause serious injury to the  operator. Al-

ways  keep  the  tip  of  the  fuel  injection  nozzle

pointed away from the  operator and into the fuel

collector and extension.

NOTICE

If  your skin  comes  into contact  with high  pressure

fuel, obtain medical assistence immediately.

NOTICE

If a fuel  injector is suspected of operating  outside of

normal parameters it  should be removed by  a quali-

fied technician.  The suspect  fuel injector  should be

taken to an authorised agent for inspection.

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.

Operate the engine at a fast idle speed in order to

identify the faulty fuel injector. Individually loosen and

tighten the union nut for the high pressure pipe to

each fuel injector. Do not loosen the union nut more

than half a turn. There will be little effect on the

engine speed when the union nut to the faulty fuel

injector is loosened.

Regular maintenance of the fuel injectors is

recommended by Perkins . The fuel injectors must be

removed and tested by an authorized agent. The fuel

injectors should not be cleaned as cleaning with

incorrect tools can damage the nozzle. The fuel

injectors should be renewed only if a fault with the

fuel injectors occurs. Some of the problems that may

indicate that new fuel injectors are needed are listed

below:

Consult your authorized Perkins dealer or your

Perkins  distributor for further assistance.

This document is printed from SPI². Not for RESALE

 

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SEBU8609

Maintenance Recommendations

Fuel System - Prime

i04145953

Fuel System - Prime

Turn the keyswitch to the ON position for 2 minutes in

order to prime the fuel system. Turn keyswitch to OFF

position, then turn on again. The engine is primed

and ready to start.

i05164991

Fuel System Secondary Filter -

Replace

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent

possible  injury,  turn  the  start  switch  off when

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

Illustration 61

g03317866

Typical example

2. Clean the outside of the fuel filter assembly (1).

3. Remove setscrew (2).

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.

4. Remove the canister (3). Ensure that any fluid is

drained into a suitable container.

NOTICE

Care  must be  taken to  ensure  that fluids  are  con-

tained  during   performance  of  inspection,   mainte-

nance, testing, adjusting and repair of the product. Be

prepared to  collect the fluid  with suitable containers

before  opening any  compartment  or disassembling

any component containing fluids.

Dispose of all fluids according to local regulations and

mandates.

Fuel Filter with Canister

1. Close the fuel supply valve.

Illustration 62

g02710378

Typical example

5. Assemble the following items: seals (8), seal (7),

canister (3) and bowl (10). Place washer (5) and

seal (6) on setscrew (2).

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93

Maintenance Recommendations

Fuel Tank Water and Sediment - Drain

6. Fasten the assembly to the fuel filter base with

setscrew (2).

Some fuel tanks use supply pipes that allow water

and sediment to settle below the end of the fuel

supply pipe. Some fuel tanks use supply lines that

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

engine is equipped with this system, regular

The fuel system will need to be primed after the new

filter is installed. Refer to this Operation and

Maintenance Manual, “Fuel System - Prime”.

maintenance of the fuel system filter is important.

Fuel Storage Tanks

i02335436

Drain the water and the sediment from the fuel

storage tank at the following intervals:

Fuel Tank Water and Sediment

- Drain

•   Weekly

•   Service intervals

•   Refill of the tank

NOTICE

Care  must be  taken to  ensure  that fluids  are  con-

tained  during   performance  of  inspection,   mainte-

nance, testing, adjusting and repair of the product. Be

prepared to  collect the fluid  with suitable containers

before  opening any  compartment  or disassembling

any component containing fluids.

This will help prevent water or sediment from being

pumped from the storage tank into the engine fuel

tank.

If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to

settle before filling the engine fuel tank. Internal

baffles in the bulk storage tank will also help trap

sediment. Filtering fuel that is pumped from the

storage tank helps to ensure the quality of the fuel.

When possible, water separators should be used.

Dispose of all fluids according to local regulations and

mandates.

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.

i05154415

Glow Plugs (ARD Combustion)

- Replace

Water can be introduced into the fuel tank when the

fuel tank is being filled.

Condensation occurs during the heating and cooling

of fuel. The condensation occurs as the fuel passes

through the fuel system and the fuel returns to the

fuel tank. This causes water to accumulate in fuel

tanks. Draining the fuel tank regularly and obtaining

fuel from reliable sources can help to eliminate water

in the fuel.

Ensure that all adjustments and repairs are

performed by authorized personnel that have the

correct training.

Drain the Water and the Sediment

Fuel tanks should contain some provision for draining

water and draining sediment from the bottom of the

fuel tanks.

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

order to drain the water and the sediment. Close the

drain valve.

Check the fuel daily. Allow five minutes after the fuel

tank has been filled before draining water and

sediment from the fuel tank.

Fill the fuel tank after operating the engine in order to

drive out moist air. This will help prevent

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

expands as the fuel gets warm. The tank may

overflow.

This document is printed from SPI². Not for RESALE

 

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SEBU8609

Maintenance Recommendations

Hoses and Clamps - Inspect/Replace

•   Cracking

•   Softness

•   Loose clamps

Replace hoses that are cracked or soft. Tighten any

loose clamps.

NOTICE

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

stall bent  or damaged lines,  tubes or hoses.  Repair

any loose  or damaged fuel  and oil  lines, tubes  and

hoses. Leaks can cause fires. Inspect all lines, tubes

and  hoses carefully.  Tighten  all connections  to the

recommended torque.  Do not clip  any other  item to

the high pressure lines.

Check for the following conditions:

•   End fittings that are damaged or leaking

•   Outer covering that is chafed or cut

Illustration 63

g03310158

Typical example

•   Exposed wire that is used for reinforcement

•   Outer covering that is ballooning locally

•   Flexible part of the hose that is kinked or crushed

•   Armoring that is embedded in the outer covering

Remove the Glow Plug for the After

Regeneration Devise (ARD)

1. Ensure that all components are clean and free from

dirt and grease. Remove protective cap (1).

A constant torque hose clamp can be used in place of

any standard hose clamp. Ensure that the constant

torque hose clamp is the same size as the standard

clamp.

2. Remove nut (2) from glow plug (4) and remove

electrical connection (3).

3. Remove glow plug (4) from ARD (5).

Due to extreme temperature changes, the hose will

harden. Hardening of the hoses will cause hose

clamps to loosen. This can result in leaks. A constant

torque hose clamp will help to prevent loose hose

clamps.

Install New Glow Plug

1. Install new glow plug (4) into ARD (5) and tighten

glow plug to a torque of 17 N·m  (150 lb in).

Each installation application can be different. The

differences depend on the following factors:

2. Install the electrical connection (3) and install nut

(2). Tighten nut (2) two a torque of 1.5 N·m

(13 lb in).

•   Type of hose

•   Type of fitting material

3. Install protective cap (1).

•   Anticipated expansion and contraction of the hose

i02813964

•   Anticipated expansion and contraction of the

fittings

Hoses and Clamps - Inspect/

Replace

Replace the Hoses and the Clamps

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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95

Maintenance Recommendations

Radiator - Clean

The coolant system and the hoses for the coolant

system are not usually supplied by Perkins . The

following text describes a typical method of replacing

coolant hoses. Refer to the OEM information for

further information on the coolant system and the

hoses for the coolant system.

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

Inspect the radiator for these items: Damaged fins,

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

debris. Clean the radiator, if necessary.

Pressurized System: Hot coolant can  cause seri-

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure   cap  slowly   in  order   to   relieve  the

pressure.

Personal injury can result from air pressure.

Personal injury can result without following prop-

er  procedure. When  using  pressure air,  wear  a

protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

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

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction to

the fan's air flow. Hold the nozzle approximately 6 mm

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

the air nozzle in a direction that is parallel with the

radiator tube assembly. This will remove debris that is

between the tubes.

2. Loosen the cooling system filler cap slowly in order

to relieve any pressure. Remove the cooling

system filler cap.

Note: Drain the coolant into a suitable, clean

container. The coolant can be reused.

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 water

in order to soften mud. Clean the core from both

sides.

3. Drain the coolant from the cooling system to a level

that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

Use a degreaser and steam for removal of oil and

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

with detergent and hot water. Thoroughly rinse the

core with clean water.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

If the radiator is blocked internally, refer to the OEM

Manual for information regarding flushing the cooling

system.

Note: For the correct coolant, see this Operation and

Maintenance Manual, “Fluid Recommendations”.

8. Refill the cooling system. Refer to the OEM

information for further information on refilling the

cooling system.

After cleaning the radiator, start the engine. Allow the

engine to operate at low idle speed for three to five

minutes. Accelerate the engine to high idle. This will

help in the removal of debris and the drying of the

core. Slowly reduce the engine speed to low idle and

then stop the engine. Use a light bulb behind the core

in order to inspect the core for cleanliness. Repeat

the cleaning, if necessary.

9. Clean the cooling system filler cap. Inspect the

cooling system filler cap's seals. Replace the

cooling system filler cap if the seals are damaged.

Install the cooling system filler cap.

Inspect the fins for damage. Bent fins may be opened

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

Welds, mounting brackets, air lines, connections,

clamps and seals. Make repairs, if necessary.

10. Start the engine. Inspect the cooling system for

leaks.

i02335774

Radiator - Clean

The radiator is not usually supplied by Perkins . The

following text describes a typical cleaning procedure

for the radiator. Refer to the OEM information for

further information on cleaning the radiator.

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SEBU8609

Maintenance Recommendations

Radiator Pressure Cap - Clean/Replace

i03639888

Radiator Pressure Cap - Clean/

Replace

A regular visual inspection of the turbocharger is

recommended. Any fumes from the crankcase are

filtered through the air inlet system. Therefore, by-

products from oil and from combustion can collect in

the turbocharger compressor housing. Over time, this

buildup can contribute to loss of engine power,

increased black smoke and overall loss of engine

efficiency.

If the turbocharger fails during engine operation,

damage to the turbocharger compressor wheel and/

or to the engine may occur. Damage to the

turbocharger compressor wheel can cause additional

damage to the pistons, the valves, and the cylinder

head.

Pressurized System: Hot coolant can  cause seri-

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure   cap  slowly   in  order   to   relieve  the

pressure.

NOTICE

Turbocharger bearing failures can cause large quanti-

ties of oil to enter the air intake and exhaust systems.

Loss of engine lubricant can  result in serious engine

damage.

NOTICE

When any  servicing or  repair of  the engine  cooling

system  is  performed  the  procedure  must  be  per-

formed with the engine on level ground. This will allow

you to accurately check the coolant level. This will al-

so help in avoiding  the risk of introducing an air lock

into the coolant system.

Minor  leakage of  oil  into a  turbocharger under  ex-

tended low idle operation should not cause problems

as  long  as a  turbocharger  bearing  failure has  not

occurred.

When a turbocharger bearing failure is  accompanied

by a  significant loss  of engine  performance, do  not

continue  engine operation  until  the turbocharger  is

renewed.

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

Loosen the cooling system filler cap slowly in order

to relieve any pressure. Remove the radiator

pressure cap.

A visual inspection of the turbocharger can minimize

unscheduled downtime. A visual inspection of the

turbocharger can also reduce the chance for potential

damage to other engine parts.

2. Check coolant level. Refer to Operation and

Maintenance Manual, “Cooling System Coolant

Level - Check”.

3. Install new radiator pressure cap.

Removal and Installation

For options regarding the removal, installation, and

replacement, consult your Perkins  dealer or your

Perkins  distributor. Refer to the Disassembly and

Assembly Manual, “Turbocharger - Remove and

Turbocharger - Install” for further information.

i02177969

Starting Motor - Inspect

Perkins  recommends a scheduled inspection of the

starting motor. If the starting motor fails, the engine

may not start in an emergency situation.

Inspecting

NOTICE

The compressor  housing for  the  turbocharger must

not be removed from the turbocharger for cleaning.

Check the starting motor for correct operation. Check

the electrical connections and clean the electrical

connections. Refer to the Systems Operation, Testing

and Adjusting Manual, “Electric Starting System -

Test” for more information on the checking procedur, e

<, P>and for specifications or consult your Perkins  dealer

or your Perkins distributor for assistance.

The actuator linkage is connected to the  compressor

housing. If the actuator linkage is moved or disturbed,

the engine may not comply with emissions legislation.

i05157183

Turbocharger - Inspect

(If Equipped)

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SEBU8609

97

Maintenance Recommendations

Walk-Around Inspection

1. Remove the pipe from the turbocharger exhaust

outlet and remove the air intake pipe to the

turbocharger. Visually inspect the piping for the

presence of oil. Clean the interior of the pipes in

order to prevent dirt from entering during

reassembly.

NOTICE

Accumulated grease and/or oil on an  engine is a fire

hazard. Remove the accumulated grease and oil. Re-

fer to  this Operation and  Maintenance Manual, “En-

gine - Clean” for more information.

2. Check for the presence of oil. If oil is leaking from

the back side of the compressor wheel, there is a

possibility of a failed turbocharger oil seal.

•   Ensure that the cooling system hoses are correctly

clamped and that the cooling system hoses are

tight. Check for leaks. Check the condition of all

pipes.

The presence of oil may be the result of extended

engine operation at low idle. The presence of oil

may also be the result of a restriction of the line for

the intake air (clogged air filters), which causes the

turbocharger to slobber.

•   Inspect the water pump for coolant leaks.

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 the parts contract.

3. Inspect the bore of the housing of the turbine outlet

for corrosion.

Excessive coolant leakage may indicate the need to

replace the water pump seal. For the removal of the

water pump and the installation of water pump and/or

seal, refer to the Disassembly and Assembly Manual,

“Water Pump - Remove and Install” for more

information or consult your Perkins dealer or your

Perkins  distributor.

4. Fasten the air intake pipe and the exhaust outlet

pipe to the turbocharger housing.

i02177973

Walk-Around Inspection

•   Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil

pan, the oil filters and the rocker cover.

Inspect the Engine for Leaks and

for Loose Connections

•   Inspect the fuel system for leaks. Look for loose

fuel line clamps and/or tie-wraps.

A walk-around inspection should only take a few

minutes. When the time is taken to perform these

checks, costly repairs and accidents can be avoided.

•   Inspect the piping for the air intake system and the

elbows for cracks and for loose clamps. Ensure

that hoses and tubes are not contacting other

hoses, tubes, wiring harnesses, etc.

For maximum engine service life, make a thorough

inspection 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:

•   Inspect the alternator belts and any accessory

drive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced as

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

carry more load than the belts that are not replaced.

The older belts are stretched. The additional load on

the new belt could cause the belt to break.

•   The guards must be in the correct place. Repair

damaged guards or replace missing guards.

•   Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system

contamination.

NOTICE

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

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

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

id levels more often than recommended until the leak

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

proved to be unwarranted.

This document is printed from SPI². Not for RESALE

 

98

SEBU8609

Maintenance Recommendations

Water Pump - Inspect

•   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.

•   Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed

wires.

•   Inspect the ground strap for a good connection

and for good condition.

•   Disconnect any battery chargers that are not

protected against the current drain of the starting

motor. Check the condition and the electrolyte

level of the batteries, unless the engine is

equipped with a maintenance free battery.

•   Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that

can not be calibrated.

i01907756

Water Pump - Inspect

A failed water pump may cause severe engine

overheating problems that could result in the following

conditions:

•   Cracks in the cylinder head

•   A piston seizure

•   Other potential damage to the engine

Note: The water pump seal is lubricated by the

coolant in the cooling system. It is normal for a small

amount of leakage to occur as the engine cools down

and parts contract.

Visually inspect the water pump for leaks. Renew the

water pump seal or the water pump if there is an

excessive leakage of coolant. Refer to the

Disassembly and Assembly Manual, “Water Pump -

Remove and Install” for the disassembly and

assembly procedure.

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SEBU8609

99

Warranty Section

Federal Emission Control Warranty

Warranty Section

As a condition of reimbursement, replaced parts and

receipted invoices must be presented at a place of

business of a Perkins distributor or your Perkins

dealer or other establishment authorized by Perkins

Engine Company limited

Warranty Information

This warranty covers the following emission-related

parts and components:

i04059789

Federal Emission Control

Warranty

•   Turbocharger System

•   Inlet Manifold

•   Fuel Injection System

Emissions Warranty

•   Crankcase Ventilation System

•   Electronic Engine Control System

•   Engine Aftertreatment System

•   NOxReduction System

The 400F diesel engines are an nonroad

compression ignition engine . Perkins Engine

Company limited warrants to the initial owner and to

the subsequent owner of the 400F diesel engines

that such an engine is:

•   AftertreatmentRegeneration Device

1. Designed, built, and equipped so that the engine

conforms, at the time of sale, with all applicable

regulations adopted by the United States

•   Miscellaneous valves, switches, hoses, clamps,

connectors, tubing, and sealing devices that are

used in the above systems

Environmental Protection Agency (EPA) .

2. Free from defects in materials and workmanship in

specific emission-related parts for the following

period:

Limitations and Responsibilities

The warranty is subject to the following conditions:

•   The warranty period is for 3000 hours or for 5

years, whichever occurs first, after the date of

delivery to the owner that operates the engine.

Perkins Engine Company limited

Responsibilities

If an emission-related part fails during any of the

warranty periods, the part will be repaired or replaced.

Any such part repaired or replaced under warranty is

warranted for the remainder of the warranty period.

During the emission warranty period, if a defect in

material or workmanship of an emission-related part

or component is found, Perkins Engine Company

limited will provide the following:

During the term of this warranty, Perkins Engine

Company limited will provide through a Perkins

distributor or your Perkins dealer or other

establishment authorized by it, repair or replacement

of any warranted part at no charge to the engine

owner.

•   New, Remanufactured or repaired parts and/or

components, approved pursuant to EPA

Regulations, required to correct the defect.

•   Reasonable and customary labor, during normal

working hours that is required to make the

warranty repair. Included is the labor in order to

remove an engine and install the engine, if

necessary.

In an emergency, repairs may be performed at any

service establishment, or by the owner, using any

replacement part. It is recommended that emission-

related parts be replaced with genuine Perkins

Engine Company limited parts.

Note: Items that are replaced under this warranty

become the property of Perkins Engine Company

limited .

Perkins Engine Company limited will reimburse the

owner for their expenses, including diagnostic

charges for such an emergency repair. These

expenses shall not exceed the Perkins Engine

Company limited suggested retail price for all

warranted parts replaced, and labor charges based

on Perkins Engine Company limited recommended

time allowance for the warranty repair and the

geographically appropriate hourly labor rate.

Owner Responsibilities

During the emission warranty period, the owner is

responsible for the following items:

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100

SEBU8609

Warranty Information

California Emission Control Warranty Statement

•   The costs in order to investigate complaints which

are not caused by a defect in Perkins Engine

Company limited material or Perkins Engine

Company limited workmanship.

Perkins Engines Company Limited warrants to the

initial owner and to the subsequent owner of the 400F

diesel engines that such an engine is:

1. Designed, built, and equipped so that the engine

conforms, at the time of sale, with all applicable

regulations adopted by the California Air

Resources Board (CARB) .

•   Providing timely notice of a warrantable failure and

promptly making the product available for repair

Limitations

2. Free from defects in materials and workmanship in

specific emission-related parts for the following

period:

Perkins Engine Company limited is not responsible

for resultant damages to an emission-related part or

component resulting from the following items:

•   The warranty period is for 3000 hours or for 5

years, whichever occurs first, after the date of

delivery to the owner that operates the engine .

•   Any application or any installation that Perkins

Engine Company limited deems improper.

•   Attachments, accessory items, or parts not sold

nor approved by Perkins Engine Company limited

If an emission-related part fails during any of the

warranty periods, the part will be repaired or

replaced. Any such part repaired or replaced under

warranty is warranted for the remainder of the

warranty period.

•   Improper engine maintenance, repair, or abuse.

•   Use of improper fuel, lubricants, or fluids.

During the term of this warranty, Perkins Engines

Company Limited will provide through a Perkins

distributor or your Perkins dealer or other

establishment authorized by it, repair or

replacement of any warranted part at no charge to

the engine owner.

•   Owners unreasonable delay in making the product

available after being notified of a potential product

problem.

This warranty is in addition to Perkins Engine

Company limited standard warranty, applicable to the

engine product involved.

In an emergency, repairs may be performed at any

service establishment, or by the owner, using any

replacement part. It is recommended that

emission-related parts be replaced with genuine

Perkins Engines Company Limited parts.

Remedies under this warranty are limited to the

provision of material and services as specified herein.

Perkins Engine Company limited is not responsible

for incidental or consequential damages, including

but not limited to downtime or loss-of-use of engine.

Perkins Engines Company Limited will reimburse

the owner for their expenses, including diagnostic

charges for such an emergency repair. These

expenses shall not exceed the Perkins Engines

Company Limited suggested retail price for all

warranted parts replaced, and labor charges

based on Perkins Engines Company Limited

recommended time allowance for the warranty

repair and the geographically appropriate hourly

labor rate.

i04059870

California Emission Control

Warranty Statement

Emissions Warranty

As a condition of reimbursement, replaced parts

and receipted invoices must be presented at a

place of business of a Perkins distributor or your

Perkins dealer or other establishment authorized

by Perkins Engines Company Limited.

The 400F engines are a nonroad compression

ignition engine .

The California Air Resources Board (CARB) and

Perkins Engines Company Limited are pleased to

explain the emission control system warranty on both

of these diesel engines.

This warranty covers the following emission-

related parts and components:

•   Turbocharger System

•   Inlet Manifold

In California, new motor vehicle engines must be

designed, built, and equipped in order to meet the

state's stringent anti-smog standards. Perkins

Engines Company Limited must warrant the

emission control system on your engine for the

duration of time listed below provided, there has not

been any abuse, neglect or improper maintenance of

your engine or your engine aftertreatmentsystem.

•   Fuel Injection System

•   Crankcase Ventilation System

•   Electronic Engine Control System

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SEBU8609

101

Warranty Information

Emissions Warranty Information

•   Engine AftertreatmentSystem

•   Any application or any installation that Perkins

Engines Company Limited deems improper.

•   NOxReduction System

•   Attachments, accessory items, or parts not sold

nor approved by Perkins Engines Company

Limited

•   Aftertreatment Regeneration Device

•   Miscellaneous valves, switches, hoses, clamps,

connectors, tubing, and sealing devices that are

used in the above systems

•   Improper engine maintenance, repair, or abuse.

•   Use of improper fuel, lubricants, or fluids.

Limitationsand Responsibilities

•   Owners unreasonable delay in making the product

available after being notified of a potential product

problem.

The warranty is subject to the following conditions:

This warranty is in addition to Perkins Engines

Company Limited standard warranty, applicable to

the engine product involved.

Perkins Engines Company Limited

Responsibilities

Remedies under this warranty are limited to the

provision of material and services as specified herein.

Perkins Engines Company Limited is not responsible

for incidental or consequential damages, including

but not limited to downtime or loss-of-use of engine.

During the emission warranty period, if a defect in

material or workmanship of an emission-related part

or component is found, Perkins Engines Company

Limited will provide the following:

•   New, Remanufactured or repaired parts and/or

components, approved pursuant to (CARB)

Regulations, required to correct the defect.

i05200893

Emissions Warranty

Information

•   Reasonable and customary labor, during normal

working hours that is required to make the

warranty repair. This includes labor in order to

remove an engine and install the engine, if

necessary.

The aftertreatmentsystem can be expected to

function properly for the life-time of the engine

(emissions durability period) subject to prescribed

maintenance requirements being followed.

Note: Items that are replaced under this warranty

become the property of Perkins Engines Company

Limited .

•   EPA

Protection Agency

United States Environmental

Owner Responsibilities

•   CARB

California Air Resources Board

During the emission warranty period, the owner is

responsible for the following items:

Note: The warranty of the engine applies to engines

that are operated within the areas of the world where

the following regulations apply: US EPATier 4

Interim, EU Stage IIIB or Japanese MLIT Step 4.  If an

engine is operated in regions of the world where

these regulations do not apply the warranty will be

void. Contact your Perkins  dealer or your Perkins

distributor for more information.

•   The costs in order to investigate complaints which

are not caused by a defect in Perkins Engines

Company Limited material or Perkins Engines

Company Limited workmanship.

•   Providing timely notice of a warrantable failure and

promptly making the product available for repair

Maintenance Recommendations

Limitations

Perkins Engines Company Limited  engines are

certified by the EPA and the CARB in order to comply

with exhaust emission standards and gaseous

emission standards that are prescribed by the law at

the time of manufacture.

Perkins Engines Company Limited is not responsible

for resultant damages to an emission-related part or

component resulting from the following items:

This document is printed from SPI². Not for RESALE

 

102

SEBU8609

Warranty Information

Emissions Warranty Information

Efficiency of the emission control and the engine

performance depends on adherence to proper

operation and maintenance recommendations and

use of recommended fuels and lubricating oils.

According to recommendations, major adjustments

and repairs should be made by your authorized

Perkins  distributor or your authorized Perkins

dealer.

fuel consumption, black smoke, misfire and rough

running engine. The fuel injector should be inspected,

tested, and replaced, if necessary. Fuel injectors can

be tested by an authorized Perkins distributor/dealer

.

TURBOCHARGER – Refer to this Operation and

Maintenance Manual, “Turbocharger - Inspect” for

information on inspection of the turbocharger.

Various chemical fuel additives which claim to reduce

visible smoke are available commercially. Although

additives have been used to solve some isolated

smoke problems in the field, additives are not

recommended for general use. The engines should

be certified without smoke depressants according to

federal smoke regulations.

ELECTRONIC ENGINE CONTROL (ECM) – The

ECM is the control computer of the engine. The ECM

provides power to the electronics. The ECM monitors

data that is input from the sensors of the engine. The

ECM acts as a governor in order to control the speed

and the power of the engine.

Take corrective steps immediately after worn parts

which may affect the emissions level are discovered

in order to ensure the proper operation of the

emission control systems. The use of genuine

Perkins  components is recommended. If the owner

uses non-Perkins  components, then the non-Perkins

components must not adversely affect the emissions

level  of the engine.

Erratic behavior of the engine may indicate a need for

repair to the ECM. Your Perkins distributor/dealer is

equipped with the necessary tools, personnel, and

procedures in order to perform this service.

The owner is encouraged to keep adequate

maintenance records. However, the absence of such

records will not invalidate the warranty. Refer to the

Operation and Maintenance Manual, “Maintenance

Log” (Reference Materials Section).

For information on the use of Aftermarket Products

and Perkins  Engines, refer to this Operation and

Maintenance Manual, “Engine Description”.

The owner may perform routine maintenance, repairs,

and other work that is outside of the warranty. The

work may be done at any repair facility. Such work

does not need to be performed at a designated

station that is determined by the warranty in order for

the warranty to remain in force.

Regular maintenance intervals with a special

emphasis on the following items are necessary in

order to keep exhaust emissions within acceptable

limits for the useful life of the engine. Refer to the

Operation and Maintenance Manual, “Severe Service

Application - Check” topic (Maintenance Section). If

the engine is operating under severe conditions,

adjust the maintenance schedule accordingly. See

your authorized Perkins distributor/dealer in order to

help analyze your specific application, operating

environment, and maintenance schedule

adjustments.

The following information is an explanation of

maintenance items for emission-related components.

See the Operation and Maintenance Manual,

“Maintenance Interval Schedule” (Maintenance

Section) for the specific interval for the following

items.

ENGINE AFTERTREATMENT SYSTEM – The

Engine Aftertreatment Systems are sensitive to the

type of fuel and lubricants that is used. Also, the

engine aftertreatment systems are sensitive to the

operating schedule. Low quality fuel, lubricants, or

fluids may cause increases in exhaust back pressure

or clogging resulting in loss of power. An authorized

Perkins distributor/dealer can determine if the engine

aftertreatmentsystems require a service.

NOx Reduction System (NRS) – The NRS is

monitored. An authorized Perkins distributor/dealer

can determine if the NRS needs service.

FUEL INJECTORS – Fuel injector tips are subject to

wear as a result of fuel contamination. This damage

can cause the following conditions: an increase in

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SEBU8609

103

Reference Information Section

Engine Protection Plans

Reference Information

Section

www.perkins.com

NOTICE

Dependant upon engine type and application.

Reference Materials

i04224089

Engine Protection Plans

(Extended Service Contract)

Extended Service Contracts-purchased in minutes,

protected for years.

Extended Service Contracts (ESC) protect you from

the stress that unexpected repair work brings to your

life by covering the cost of getting your engine up and

running again. Unlike other extended warranties,

Perkins  Platinum ESC protects you against all

component part failures.

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

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

reality.

Why buy an Extended Service Contract?

1. No surprises - total protection from unexpected

repair cost (parts, labor, and travel).

2. Enjoy longer lasting product support from Perkins

global network.

3. Genuine Perkins  parts ensure continued engine

performance.

4. Highly trained technicians carry out all repairs.

5. Transferable coverage should you sell your

machine.

Flexible coverage provides the right level of

protection for your Perkins  Engine. Coverage can be

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

40,000

You can buy an ESC at any time during standard

warranty - even the last day!

Each Perkins  Distributor has highly trained and

experienced Perkins  Product Support Service

Technicians. The Support Service are equipped, and

available around the clock to get your engine running

again with the minimum of downtime. Buying an ESC

means that you get all this for free.

To purchase an Extended Service Contract, is quick

and simple! Contact your local Perkins Distributor

now and the distributor can provide you with a quote

in minutes. You can locate your nearest Perkins

Distributor by visiting:

This document is printed from SPI². Not for RESALE

 

104

SEBU8609

Index Section

Index

A

Coolant (ELC) - Change.................................. 79

Drain ............................................................ 79

Fill................................................................. 80

Flush ............................................................ 80

Coolant Level - Check ..................................... 80

Engines With a Coolant Recovery Tank....... 80

Engines Without a Coolant Recovery Tank . 81

Coolant Temperature Regulator - Replace...... 82

Cooling System Supplemental Coolant

Additive (SCA) - Test/Add.............................. 82

Add the SCA, If Necessary.......................... 82

Test for SCA Concentration ......................... 82

Crankcase Breather (Canister) - Replace ....... 83

Crushing Prevention and Cutting Prevention ...11

After Starting Engine........................................ 47

After Stopping Engine...................................... 56

Alarms and Shutoffs ........................................ 30

Alarms.......................................................... 30

Shutoffs........................................................ 30

Testing.......................................................... 30

Alternator - Inspect .......................................... 73

Alternator and Fan Belts - Inspect/Adjust........ 74

Adjustment................................................... 74

Inspection..................................................... 74

Alternator and Fan Belts - Replace.................. 75

B

Battery - Replace............................................. 75

Battery Electrolyte Level - Check .................... 75

Battery or Battery Cable - Disconnect ............. 76

Before Starting Engine ...............................12, 45

Belts - Inspect/Adjust/Replace (Air Pump

Belt)................................................................ 76

Adjust........................................................... 77

Inspection..................................................... 76

Belts - Inspect/Replace (Air Pump belt)........... 77

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

Batteries......................................................... 9

Coolant........................................................... 9

Induction System ........................................... 9

Oils................................................................. 9

D

Diagnostic Lamp.............................................. 43

Diesel Particulate Filter - Clean....................... 84

Diesel Particulate Filter Regeneration............. 48

Modes of Regeneration................................ 49

Regeneration............................................... 48

Regeneration Indicators............................... 48

Regeneration Switch.................................... 49

Soot Level Monitoring and Indicators........... 49

E

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

Grounding Practices .................................... 13

Emergency Stopping....................................... 56

Emissions Certification Film ............................ 26

Emissions Warranty Information.................... 101

Maintenance Recommendations............... 101

Engine - Clean................................................. 85

Aftertreatment.............................................. 85

Engine Air Cleaner Element - Replace............ 85

Engine Air Cleaner Service Indicator -

Inspect........................................................... 85

Test the Service Indicator............................. 86

Engine Air Precleaner - Check/Clean.............. 86

Engine Diagnostics.......................................... 43

Engine Electronics........................................... 14

Engine Mounts - Inspect.................................. 86

Engine Oil and Filter - Change ........................ 87

Drain the Engine Oil..................................... 87

Fill the Engine Crankcase............................ 88

Replace the Oil Filter.................................... 88

C

California Emission Control Warranty

Statement .................................................... 100

Emissions Warranty................................... 100

Cold Weather Operation.................................. 52

Hints for Cold Weather Operation................ 52

Idling the Engine .......................................... 53

Recommendations for Coolant Warm Up .... 53

Recommendations for the Coolant .............. 53

Viscosity of the Engine Lubrication Oil......... 53

Cold Weather Starting ..................................... 45

Configuration Parameters................................ 44

Coolant (Commercial Heavy-Duty) - Change.. 77

Drain ............................................................ 78

Fill................................................................. 78

Flush ............................................................ 78

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SEBU8609

105

Index Section

Engine Oil Level - Check................................. 86

Engine Operation............................................. 48

Engine Operation and Active Regeneration

................................................................... 48

Reduction of Particulate Emissions ............. 48

Engine Operation with Active Diagnostic

Fuel System - Prime........................................ 92

Fuel System Secondary Filter - Replace......... 92

Fuel Filter with Canister ............................... 92

Fuel Tank Water and Sediment - Drain............ 93

Drain the Water and the Sediment............... 93

Fuel Storage Tanks...................................... 93

Fuel Tank ..................................................... 93

Codes ............................................................ 43

Engine Operation with Intermittent

Diagnostic Codes........................................... 43

Engine Protection Plans (Extended Service

Contract)...................................................... 103

Engine Starting...........................................12, 45

Engine Stopping.........................................13, 56

Engine Valve Lash - Check.............................. 89

G

Gauges and Indicators .................................... 30

AftertreatmentLamps .................................. 31

Indicators and Lamps................................... 31

General Hazard Information.............................. 5

Containing Fluid Spillage............................... 7

Dispose of Waste Properly............................. 8

Fluid Penetration............................................ 7

Inhalation ....................................................... 8

Pressure Air and Water.................................. 7

General Information......................................... 15

Glow Plugs (ARD Combustion) - Replace....... 93

Remove the Glow Plug for the After

F

Fan Clearance - Check.................................... 90

Fault Logging................................................... 43

Features and Controls..................................... 30

Federal Emission Control Warranty................. 99

Emissions Warranty..................................... 99

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

Fire Extinguisher...........................................11

Lines, Tubes, and Hoses ..............................11

Regeneration ................................................11

Fluid Recommendations.......................58, 62, 65

Diesel Fuel Characteristics ......................... 67

Diesel Fuel Requirements ........................... 65

ELC Cooling System Maintenance.............. 60

Engine Oil .................................................... 63

General Coolant Information........................ 58

General Information..................................... 65

General Lubricant Information ..................... 62

Foreword............................................................ 4

California Proposition 65 Warning ................. 4

Literature Information..................................... 4

Maintenance.................................................. 4

Maintenance Intervals.................................... 4

Operation....................................................... 4

Overhaul ........................................................ 4

Safety............................................................. 4

Fuel and the Effect from Cold Weather............ 54

Fuel Conservation Practices............................ 50

Fuel Filter (In-Line) - Replace.......................... 90

Fuel Injector - Test/Change.............................. 91

Identification of a suspect Fuel Injector........ 91

Fuel Related Components in Cold Weather.... 55

Fuel Filters ................................................... 55

Fuel Heaters ................................................ 55

Fuel Tanks.................................................... 55

Regeneration Devise (ARD) ...................... 94

H

Hoses and Clamps - Inspect/Replace............. 94

Replace the Hoses and the Clamps ............ 94

I

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

L

Lifting and Storage........................................... 28

M

Maintenance Interval Schedule....................... 73

Commissioning............................................ 73

Daily............................................................. 73

Every 1000 Service Hours........................... 73

Every 12 000 Service Hours or 6 Years....... 73

Every 2000 Service Hours........................... 73

Every 250 Service Hours or 6 Months ......... 73

Every 3000 Service Hours........................... 73

Every 3000 Service Hours or 2 Years.......... 73

Every 50 Service Hours or Weekly .............. 73

Every 500 Service Hours............................. 73

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106

SEBU8609

Index Section

Every 500 Service Hours or 1 Year.............. 73

When Required............................................ 73

Maintenance Recommendations..................... 70

Maintenance Section....................................... 57

Model View Illustrations (Engines and

Aftertreatment)............................................... 15

403F-15T ..................................................... 15

404F-22........................................................ 16

404F-22T ..................................................... 17

AftertreatmentSystem.................................  20

Engine with Low Mounted Air Pump............ 22

Off Engine Parts........................................... 21

Monitoring System........................................... 32

ProgrammableOptions and Systems

Refill Capacities............................................... 57

Cooling System............................................ 57

Lubrication System ...................................... 57

S

Safety Messages............................................... 5

(1) Universal Warning .................................... 5

Safety Section ................................................... 5

Self-Diagnostics............................................... 43

Sensors and Electrical Components

(Engine and Aftertreatment) .......................... 33

Severe Service Application.............................. 71

Environmental Factors................................. 71

Incorrect Maintenance Procedures.............. 72

Incorrect Operating Procedures................... 72

Starting Motor - Inspect ................................... 96

Starting the Engine.......................................... 46

Starting the Engine ...................................... 46

Starting with Jump Start Cables ...................... 46

Stopping the Engine ........................................ 56

System Pressure Release............................... 70

Coolant System............................................ 70

Engine Oil .................................................... 70

Fuel System................................................. 70

Operation ................................................... 32

Monitoring System (Engine Warning

Indicators)...................................................... 33

Mounting and Dismounting.............................. 12

O

Operation Section............................................ 28

Overspeed....................................................... 33

P

Plate Locations and Film Locations................. 26

Product Description......................................... 22

AftermarketProducts and Perkins  Engines

................................................................... 25

Electronic Engine Features.......................... 24

Engine Diagnostics...................................... 24

Engine Service Life...................................... 24

Engine Specifications .................................. 23

Product Identification Information.................... 26

Product Information Section ............................ 15

Product Lifting.................................................. 28

Lifting Eyes with Top Mounted Aftertreatment

................................................................... 28

Product Storage (Engine and

T

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

Turbocharger - Inspect (If Equipped)............... 96

Inspecting..................................................... 96

Removal and Installation.............................. 96

W

Walk-Around Inspection .................................. 97

Inspect the Engine for Leaks and for Loose

Connections............................................... 97

Warranty Information....................................... 99

Warranty Section............................................. 99

Water Pump - Inspect...................................... 98

Welding on Engines with Electronic Controls.. 70

Aftertreatment)............................................... 28

Condition for Storage................................... 28

R

Radiator - Clean............................................... 95

Radiator Pressure Cap - Clean/Replace......... 96

Reference Information..................................... 27

Record for Reference................................... 27

Reference InformationSection...................... 103

Reference Materials ...................................... 103

This document is printed from SPI². Not for RESALE

 

Product and Dealer Information

Note: For

product identification plate locations, see the section “Product Identification

Information” in the Operation and Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identification Number:

Engine Serial Number:

Transmission

Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment

Number:

Dealer Information

Name:

Branch:

Address:

Dealer

Phone

Hours

Contact

Number

Sales:

Parts:

Service:

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©2013Perkins Engines Company Limited

All Rights Reserved

This document is printed from SPI². Not for RESALE