Operation and Maintenance Manual: 1204F-E44TA and 1204F-E44TTA Industrial Engines
Operation and Maintenance Manual: 1204F-E44TA and 1204F-E44TTA Industrial Engines
Operation and Maintenance Manual: 1204F-E44TA and 1204F-E44TTA Industrial Engines
January 2017
Operation and
Maintenance
Manual
1204F-E44TA and 1204F-E44TTA
Industrial Engines
MT1 1-UP (Engine)
MU1 1-UP (Engine)
MW1 1-UP (Engine)
This document has been printed from SPI2. NOT FOR RESALE
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
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SEBU9063-03 3
Table of Contents
Refill Capacities............................................... 78
Foreword ........................................................... 4
Maintenance Recommendations .................... 95
Safety Section
Maintenance Interval Schedule....................... 98
Safety Messages............................................... 5
Engine Starting................................................ 17
Electrical System............................................. 18
Engine Electronics........................................... 19
Operation Section
Engine Starting................................................ 66
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4 SEBU9063-03
Foreword
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SEBU9063-03 5
Safety Section
Safety Messages
Safety Section
i05670468
Safety Messages
Illustration 1 g01154807
Typical example
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Safety Section
Safety Messages
Illustration 2 g03404355
Illustration 3 g02382677
Typical example
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SEBU9063-03 7
Safety Section
Safety Messages
Illustration 4 g03404354
Ether Warning
An ether warning label will be installed on the air
cleaner or close to the air cleaner. The location will
depend on the application.
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8 SEBU9063-03
Safety Section
General Hazard Information
General Hazard Information Unless other instructions are provided, perform the
maintenance under the following conditions:
Do not allow unauthorized personnel on the engine, • Do not attempt any repairs or any adjustments to
or around the engine when the engine is being the engine while the engine is operating.
serviced.
• Do not attempt any repairs that are not
• Tampering with the engine installation or understood. Use the proper tools. Replace any
tampering with the OEM supplied wiring can be equipment that is damaged or repair the
dangerous. Personal injury, death and/or engine equipment.
damage could result.
• For initial start-up of a new engine or for starting
• Vent the engine exhaust to the outside when the an engine that has been serviced, make
engine is operated in an enclosed area. provisions to stop the engine if an overspeed
occurs. The stopping of the engine may be
• If the engine is not running, do not release the accomplished by shutting off the fuel supply and/
secondary brake or the parking brake systems or the air supply to the engine. Ensure that only
unless the vehicle is blocked or unless the vehicle the fuel supply line is shut off. Ensure that the fuel
is restrained. return line is open.
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SEBU9063-03 9
Safety Section
General Hazard Information
• Start the engine from the operators station (cab). • Use all cleaning solutions with care.
Never short across the starting motor terminals or
the batteries. This action could bypass the engine • Report all necessary repairs.
neutral start system and/or the electrical system
could be damaged. Unless other instructions are provided, perform
the maintenance under the following conditions:
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the • The engine is stopped. Ensure that the engine
engine and operate the engine in a well ventilated cannot be started.
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside. • Disconnect the batteries when maintenance is
performed or when the electrical system is
Cautiously remove the following parts. To help serviced. Disconnect the battery ground leads.
prevent spraying or splashing of pressurized fluids, Tape the leads in order to help prevent sparks.
hold a rag over the part that is being removed.
• Do not attempt any repairs that are not
• Filler caps understood. Use the proper tools. Replace any
equipment that is damaged or repair the
• Grease fittings equipment.
• Pressure taps
Pressurized Air and Water
• Breathers
Pressurized air and/or water can cause debris and/or
• Drain plugs hot water to be blown out. This action could result in
personal injury.
Use caution when cover plates are removed.
When pressurized air and/or pressurized water is
Gradually loosen, but do not remove the last two
used for cleaning, wear protective clothing, protective
bolts or nuts that are located at opposite ends of the shoes, and eye protection. Eye protection includes
cover plate or the device. Before removing the last
goggles or a protective face shield.
two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure. The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
Illustration 7 g00702020
components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
information for any procedures that are required to
• Wear a hard hat, protective glasses, and other relieve the hydraulic pressure.
protective equipment, as required.
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Safety Section
General Hazard Information
Inhalation
Illustration 8 g00687600
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SEBU9063-03 11
Safety Section
Burn Prevention
• Avoid brushing materials that contain asbestos. DEF is not expected to produce significant adverse
health effects when the recommended instructions
• Avoid grinding materials that contain asbestos. for use are followed.
• Use a wet method in order to clean up asbestos • Do not breathe DEF vapor or mist.
materials.
• Do not eat, drink, or smoke when using DEF.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be • Avoid DEF contact with eyes, skin, and clothing.
used.
• Wash thoroughly after handling DEF.
• Use exhaust ventilation on permanent machining
jobs. i06078513
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12 SEBU9063-03
Safety Section
Burn Prevention
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SEBU9063-03 13
Safety Section
Fire Prevention and Explosion Prevention
Aftertreatment System and Diesel Store fuels and lubricants in correctly marked
Exhaust Fluid containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
Diesel Exhaust Fluid (DEF) temperatures can reach containers. Do not smoke in areas that are used for
65° to 70°C (149.° to 126°F) during normal engine storing flammable materials.
operation. Stop the engine. Wait for 15 minutes in Do not expose the engine to any flame.
order to allow the DEF system to be purged and the
DEF to cool before service or repair is performed. Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line, a
i05670934 tube, or a seal failure. Exhaust shields must be
installed correctly.
Fire Prevention and Explosion Do not weld on lines or tanks that contain flammable
Prevention fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Ensure that all
electrical wires are correctly installed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
or sparking.
Illustration 11 g00704000
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14 SEBU9063-03
Safety Section
Fire Prevention and Explosion Prevention
Use caution when you are refueling an engine. Do Gases from a battery can explode. Keep any open
not smoke while you are refueling an engine. Do not flames or sparks away from the top of a battery. Do
refuel an engine near open flames or sparks. Always not smoke in battery charging areas.
stop the engine before refueling.
Never check the battery charge by placing a metal
Avoid static electricity risk when fueling. Ultra-low object across the terminal posts. Use a voltmeter or a
Sulfur Diesel fuel (ULSD fuel) poses a greater static hydrometer.
ignition hazard than earlier diesel formulations with a
higher sulfur content. Avoid death or serious injury Incorrect jumper cable connections can cause an
from fire or explosion. Consult your fuel or fuel explosion that can result in injury. Refer to the
system supplier to ensure that the delivery system is Operation Section of this manual for specific
in compliance with fueling standards for proper instructions.
grounding and bonding practices.
Do not charge a frozen battery. A frozen battery may
cause an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Ether
Ether is flammable and poisonous.
Do not smoke while you are replacing an ether
cylinder or while you are using an ether spray.
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SEBU9063-03 15
Safety Section
Crushing Prevention and Cutting Prevention
Do not store ether cylinders in living areas or in the Chips or other debris may fly off objects when objects
engine compartment. Do not store ether cylinders in are struck. Before objects are struck, ensure that no
direct sunlight or in temperatures above 49° C one will be injured by flying debris.
(120° F). Keep ether cylinders away from open
flames or sparks. i05768982
Replace the parts if any of the following conditions Refer to the OEM for the location of foot and hand
are present: holds for your specific application.
i02143194
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16 SEBU9063-03
Safety Section
High Pressure Fuel Lines
Illustration 14 g03404398
(1) High-pressure line (4) High-pressure line (7) Fuel transfer line that is high pressure
(2) High-pressure line (5) High-pressure fuel manifold (rail)
(3) High-pressure line (6) High-pressure line
The high-pressure fuel lines are the fuel lines that are Visually inspect the high-pressure fuel lines before
between the high-pressure fuel pump and the high- the engine is started. This inspection should be each
pressure fuel manifold and the fuel lines that are day.
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel If you inspect the engine in operation, always use the
systems. proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
The different is because of the following items: Maintenance Manual, “General hazard Information”.
• The high-pressure fuel lines are constantly • Inspect the high-pressure fuel lines for damage,
charged with high pressure. deformation, a nick, a cut, a crease, or a dent.
• The internal pressures of the high-pressure fuel • Do not operate the engine with a fuel leak. If there
lines are higher than other types of fuel system. is a leak, do not tighten the connection in order to
stop the leak. The connection must only be
• The high-pressure fuel lines are formed to shape tightened to the recommended torque. Refer to
and then strengthened by a special process. Disassembly and Assembly, “Fuel injection lines -
Remove and Fuel injection lines - Install”.
Do not step on the high-pressure fuel lines. Do not
deflect the high-pressure fuel lines. Do not bend or • If the high-pressure fuel lines are torqued correctly
strike the high-pressure fuel lines. Deformation or and the high-pressure fuel lines are leaking, the
damage of the high-pressure fuel lines may cause a
point of weakness and potential failure. high-pressure fuel lines must be replaced.
Do not check the high-pressure fuel lines with the • Ensure that all clips on the high-pressure fuel lines
engine or the starting motor in operation. After the are in place. Do not operate the engine with clips
engine has stopped, you must wait for 10 minutes in that are damaged, missing, or loose.
order to allow the fuel pressure to be purged from the
high-pressure fuel lines before any service or repair • Do not attach any other item to the high-pressure
is performed on the engine fuel lines. The 10 minute fuel lines.
wait will also allow static charge to dissipate from the
low-pressure fuel system. • Loosened high-pressure fuel lines must be
replaced. Also removed high-pressure fuel lines
Do not loosen the high-pressure fuel lines in order to must be replaced. Refer to Disassembly and
remove air from the fuel system. This procedure is assembly manual, “ Fuel Injection Lines - Install”.
not required.
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SEBU9063-03 17
Safety Section
Before Starting Engine
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18 SEBU9063-03
Safety Section
Electrical System
Use the Emergency Stop Button (if equipped) ONLY Grounding Practices
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled.
To stop an electronically controlled engine, cut the
power to the engine and/or shutting off the air supply
to the engine.
i05380506
Electrical System
Illustration 16 g03404412
Typical example
(4) Ground to the battery
(5) Ground to the cylinder block
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SEBU9063-03 19
Safety Section
Engine Electronics
Uncontrolled electrical circuit paths can result in The following monitored engine operating conditions
damage to the crankshaft bearing journal surfaces and components have the ability to limit engine
and to aluminum components. speed and/or the engine power:
Engines that are installed without engine-to-frame • Engine Coolant Temperature
ground straps can be damaged by electrical
discharge. • Engine Oil Pressure
To ensure that the engine and the engine electrical • Engine Speed
systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be • Intake Manifold Air Temperature
used. This path may be provided by way of a direct
engine ground to the frame. • Engine Intake Throttle Valve Fault
The connections for the grounds should be tight and • Wastegate Regulator
free of corrosion. The engine alternator must be
grounded to the negative “-” battery terminal with a • Supply Voltage to Sensors
wire that is adequate to handle the full charging
current of the alternator. • Fuel Pressure in Manifold (Rail)
The power supply connections and the ground • NOx Reduction System
connections for the engine electronics should always
be from the isolator to the battery. • Engine Aftertreatment System
i06677046
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
Engine Electronics monitoring control will be similar for all engines.
• Derate
• Shutdown
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20 SEBU9063-03
Product Information Section
General Information
Product Information
Section
General Information
i05673429
Illustration 17 g03404421
Typical example
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SEBU9063-03 21
Product Information Section
Model View Illustrations
Illustration 18 g03404422
Typical example
(1) Front lifting eye (6) Priming/tranfer fuel pump (11) Oil sampling valve
(2) Crankcase breather (7) In line fuel filter (12) High-pressure fuel pump
(3) Secondary fuel filter (8) Oil level gauge (dipstick) (13) Oil filler
(4) Primary fuel filter (9) Oil drain plug
(5) Electronic Control Module (10) Oil filter
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22 SEBU9063-03
Product Information Section
Model View Illustrations
Illustration 19 g03404423
Typical example
(14) Air intake (16) Water pump (18) Tensioner
(15) Coolant outlet (17) Coolant intake (19) Belt
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SEBU9063-03 23
Product Information Section
Model View Illustrations
Illustration 20 g03404515
Typical example
(20) Back pressure valve (25) Starter solenoid (30) Flywheel housing
(21) High-pressure turbocharger (26) Starting motor (31) NOx reduction cooler
(22) Low-pressure turbocharger (27) Starter relay (32) Rear lifting eye
(23) Alternator (28) Oil drain tap
(24) Refrigerant compressor (29) Flywheel
Aftertreatment Systems
Two different types of aftertreatment are available,
the aftertreatment must be matched to the engine
power.
• Diesel Oxidation Catalyst (DOC) and Selective
Catalytic Reduction (SCR)
• Diesel Oxidation Catalyst (DOC) Diesel
Particulate Filter (DPF) and Selective Catalytic
Reduction (SCR)
For a general description of the aftertreatment refer
to this Operation and Maintenance Manual, “Product
Description” for more information.
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24 SEBU9063-03
Product Information Section
Model View Illustrations
Illustration 21 g03416433
Typical example
(1) SCR (3) Outlet for Exhaust gas (5) DOC
(2) Identification module (4) Mixer (6) Inlet for Exhaust gas
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SEBU9063-03 25
Product Information Section
Model View Illustrations
Illustration 22 g03713347
Typical example
(1) Intake for exhaust gas (3) Mixer (5) Outlet for exhaust gas
(2) DPF (4) SCR
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Product Information Section
Product Description
Illustration 23 g03700576
Typical example
(1) DEF tank and header unit (4) DEF filter (7) Ammonia sensor
(2) DEF filler cap (5) NOx sensors and controls (8) Control for ammonia sensor
(3) Pump electronic unit (6) Coolant control valve (9) DEF heated line
The ammonia sensor and control will only be • Model MT aftertreatment DOC and SCR
installed on the DOC and SCR system.
• Model MU aftertreatment DOC and SCR
i06215625
• Model MW aftertreatment DOC, DPF, and SCR
Product Description The aftertreatment system require Diesel Exhaust
Fluid (DEF) in order to operate correctly.
The Perkins 1204F-E44TA and the 1204F-E44TTA
The 1204F industrial engine has two engine variants. industrial engines have the following characteristics.
The 1204F-E44TA is a single turbocharged engine.
The 1204F-E44TTA is a series turbocharged engine • In-line 4 cylinder
The 1204F-E44TA engine has a Diesel Oxidation • 4 stroke cycle
Catalyst (DOC) and Selective Catalytic Reduction
(SCR) aftertreatment system and the engine model is • Four valves per cylinder
MT.
• Single turbocharger engine
The 1204F-E44TTA engine can have two different
aftertreatment systems. For the DOC and SCR • Series turbochargers engine
system, the engine model is MU.
• Aftertreatment system
The aftertreatment systems Diesel Oxidation Catalyst
(DOC) Diesel Particulate Filter (DPF) and Selective
Catalytic Reduction (SCR) system the engine model
is MW.
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SEBU9063-03 27
Product Information Section
Product Description
The front end of the engine is opposite the flywheel Rotation (flywheel end) Counterclockwise
end of the engine. The left and the right sides of the (1) The operating rpm is dependent on the engine rating, the appli-
engine are determined from the flywheel end. The cation, and the configuration of the throttle.
number 1 cylinder is the front cylinder.
Electronic Engine Features
The engine operating conditions are monitored. The
Electronic Control Module (ECM) controls the
response of the engine to these conditions and to the
demands of the operator. These conditions and
operator demands determine the precise control of
fuel injection by the ECM. The electronic engine
control system provides the following features:
• Engine monitoring
Illustration 24 g01187485
• Injection timing control
(A) Exhaust valves • System diagnostics
(B) Inlet valves
• Low temperature regeneration
Table 1
1204F-E44TA and 1204F-E44TTA Engine Specifications For more information on electronic engine features,
refer to the Operation and Maintenance Manual,
Operating Range (rpm) 800 to 2200 (1) “Features and Controls” topic (Operation Section).
Number of Cylinders 4 In-Line
Engine Diagnostics
Bore 105 mm (4.13 inch)
Stroke 127 mm (4.99 inch) The engine has built-in diagnostics in order to ensure
that the engine systems are functioning correctly. The
Power Single turbocharger charge operator will be alerted to the condition by a “Stop or
cooled Warning” lamp. Under certain conditions, the engine
66 to 110 kW horsepower and the vehicle speed may be limited.
(88.506 to 147.51 hp) The electronic service tool may be used to display
the diagnostic codes.
Series turbochargers charge
cooled There are three types of diagnostic codes: active,
105 to 129.5 kW logged and event.
(140.80 to 173.65 hp)
Most of the diagnostic codes are logged and stored in
Aspiration Single Turbocharged charge
cooled
the ECM. For additional information, refer to the
Operation and Maintenance Manual, “Engine
Series turbochargers charge
Diagnostics” topic (Operation Section).
cooled
(continued)
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28 SEBU9063-03
Product Information Section
Product Description
The ECM provides an electronic governor that The engine is connected by a flexible pipe to the
controls the injector output in order to maintain the CEM. The exhaust gases pass through the DOC and
desired engine rpm. then the mixer where the gases are mixed with the
injected urea. The mixture then enters the SCR
Engine Cooling and Lubrication catalyst. Here the NOx in the exhaust reacts with the
ammonia from the injected urea to split the gases into
nitrogen and oxygen constituents. The SCR catalyst
The cooling system and lubrication system consists includes an ammonia oxidation section (AMOX) to
of the following components: clean up any remaining ammonia before the gases
• Gear-driven centrifugal water pump exit the system.
For the DOC, DPF and SCR aftertreatment
• Water temperature regulator which regulates the configurations the CEM has four main components
engine coolant temperature again: DOC and Diesel Particulate Filter (DPF) in the
first unit, the mixer, and the SCR.
• Gear-driven rotor type oil pump
In this instance the only differences to the operation
• Oil cooler described above is that the particulate matter soot
and ash are trapped by the DPF. A passive
The engine lubricating oil is supplied by a rotor type regeneration process is used to ensure that normal
oil pump. The engine lubricating oil is cooled and the operation of the engine removes the soot. The ash
engine lubricating oil is filtered. The bypass valve can remains in the DPF and must be removed at an
provide unrestricted flow of lubrication oil to the engine overhaul.
engine if the oil filter element should become
plugged.
Cooling and Purging of the DEF Lines
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper After key-off, the DEF pump will circulate the DEF
operation and maintenance recommendations. fluid for a given time, in order to cool the DEF injector.
Engine performance and efficiency also depend on Also, the DEF pump will purge the DEF system of
the use of recommended fuels, lubrication oils, and fluid to protect the system from freeze of the DEF
coolants. Refer to this Operation and Maintenance fluid in cold conditions.
Manual, “Maintenance Interval Schedule” for more
information on maintenance items. With the DOC and SCR aftertreatment system the
cooling and purging will take a minimum of 3 minutes
and a maximum of 10 minutes. The time taken will
Aftertreatment System depend on the temperature with the aftertreatment
system.
The aftertreatment system is approved for use by
Perkins. In order to be emission-compliant only the When the DOC, DPFand SCR system is operating
approved Perkins aftertreatment system or approved with exhaust gas temperatures below 425° C
components must be used on a Perkins engine. (797° F) before key-off, the cooling and purging will
also take 6 minutes When the DOC, DPF, and SCR
aftertreatment system operates at temperatures
Clean Emission Module (CEM) above 425° C (797° F), and key-off occurs the
cooling and purging will take a maximum of 15
The function of the CEM is to ensure that the engine minutes.
exhaust meets the required emissions regulation for
the country of operation. For example, the maximum cool-down and purge
time is only likely to be encountered in a certain
There are two configurations of the CEM. combination. Full-load rated speed operation and the
DPF in a regeneration mode occurring
• Diesel Oxidation Catalyst (DOC) and Selective simultaneously, immediately before key-off.
Catalytic Reduction (SCR)
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SEBU9063-03 29
Product Information Section
Product Description
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30 SEBU9063-03
Product Information Section
Product Identification Information
Product Identification
Information
i05673551
Illustration 26 g01094203
Aftertreatment Systems
Two different aftertreatment systems are available.
• Diesel Oxidation Catalyst (DOC) and Selective
Catalytic Reduction (SCR)
• Diesel Oxidation Catalyst (DOC) Diesel
Particulate Filter (DPF) and Selective Catalytic
Reduction (SCR)
Illustration 25 g03404834
Location of serial number plate
• MT Type of engine
• ***** The list number of the engine
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SEBU9063-03 31
Product Information Section
Emissions Certification Film
Record all the information on the serial plate for your i05673571
aftertreatment system. The information will be
required by your Perkins distributors. Emissions Certification Film
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32 SEBU9063-03
Product Information Section
Reference Information
Aftertreatment Systems
Clean Emission Module Part Number
Clean Emission Module Serial Number
Dosing Control Unit Part Number
Diesel Exhaust Fluid (DEF) Filter Part Number
Illustration 30 g03598056
i05768984
Reference Information
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SEBU9063-03 33
Operation Section
Lifting and Storage
Operation Section
Product Lifting
(Aftertreatment Systems)
Illustration 31 g03417158
Typical example
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34 SEBU9063-03
Operation Section
Aftertreatment Systems
Illustration 32 g03713453
Typical example
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SEBU9063-03 35
Operation Section
Product Lifting
Some applications may require a frame or jig in order Engine and Aftertreatment Lifting
to lift the CEM. A frame or jig must only be connected
to the cradle of the CEM. Refer to the original Eyes
equipment manufacture for more information.
i06891469
Product Lifting
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Re-
member that the capacity of an eyebolt is less as the
angle between the supporting members and the ob-
ject becomes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
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36 SEBU9063-03
Operation Section
Product Lifting
Illustration 35 g03674679
The front lifting eye (3) for the engine only is installed
by two bolts. The rear lifting eye of engine only can
be identified by the design.
Illustration 34 g03674859
Typical example
Illustration 36 g06151233
Typical example
(5) Lifting eyes for factory installed radiators.
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SEBU9063-03 37
Operation Section
Product Storage
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38 SEBU9063-03
Operation Section
Engine and Aftertreatment
2. Fill the tank with DEF that meet all the requirement 35° C (95° F)(1) 6 months
defined in ISO 22241-1. (1) At 35° C, significant degradation can occur. Check every batch
before use.
3. Ensure that all DEF lines and electrical connection
are connected prior to prevent crystal from
forming.
4. Ensure that the DEF filler cap is correctly installed.
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SEBU9063-03 39
Operation Section
Features and Controls
Features and Controls Fuel rail pressure – The fuel rail pressure sensor
measures the high pressure or low pressure in the
fuel rail. The ECM will Check the pressure.
i05768989
Engine oil pressure – The engine oil pressure
Alarms and Shutoffs sensor indicates when oil pressure drops below rated
system pressure, at a set engine speed.
Engine overspeed – If, the engine rpm exceeds the
overspeed setting the alarm will be activated.
Shutoffs
Air filter restriction – The switch checks the air filter
The shutoffs are electrically operated or mechanically when the engine is operating.
operated. The electrically operated shutoffs are
controlled by the Electronic Control Module (ECM). User-defined switch – This switch can shut down
the engine remotely.
Shutoffs are set at critical levels for the following Water in fuel switch – This switch checks for water
items: in the primary fuel filter when the engine is operating.
• Operating temperature Fuel temperature – The fuel temperature sensor
monitors the pressurized fuel in the high-pressure
• Operating pressure fuel pump.
• Operating level Coolant temperature – The coolant temperature
sensor indicates high jacket water coolant
• Operating rpm temperature.
The particular shutoff may need to be reset before
the engine will start. Note: The sensing element of the coolant
temperature sensor must be submerged in coolant in
NOTICE order to operate.
Always determine the cause of the engine shutdown.
Make necessary repairs before attempting to restart Engines may be equipped with alarms in order to
the engine. alert the operator when undesirable operating
conditions occur.
• The resetting procedure that is required to restart If corrective measures are not taken within a
the engine reasonable time, engine damage could result. The
alarm will continue until the condition is corrected.
The alarm may need to be reset.
Alarms
Note: If installed, the coolant level switch and the oil
The alarms are electrically operated. The operations level switch are indicators. Both switches should only
of the alarms are controlled by the ECM. be operated when the application is on level ground
and the engine RPM is zero.
The alarm is operated by a sensor or by a switch.
When the sensor or the switch is activated, a signal is
sent to the ECM. An event code is created by the Clean Emission Module (CEM)
ECM. The ECM will send a signal in order to
illuminate the lamp. • Diesel Oxidation Catalyst (DOC)
Your engine may be equipped with the following • Selective Catalyst Reduction (SCR)
sensors or switches:
• Diesel Particulate Filter (DPF)
Intake manifold air temperature – The intake
manifold air temperature sensor indicates high intake DOC and SCR System
air temperature.
• Temperature Sensor before DOC
Intake manifold pressure – The intake manifold
pressure sensor checks the rated pressure in the • NOx Sensor
engine manifold.
This document has been printed from SPI2. NOT FOR RESALE
40 SEBU9063-03
Operation Section
Selective Catalytic Reduction Warning System
• SCR Temperature Sensor The DEF level sensor, DEF temperature sensor, and
the Dosing control unit all connect with the engine
• Ammonia Sensor ECM. If the ECM determines that any of the signals
are out of the specified range, an alarm will be
Temperature Sensor before DOC – This sensor triggered.
monitors the gas temperature that is entering the
DOC
Testing
NOx Sensor – Two NOx sensors monitor the NOx
concentration within the exhaust gas before and after Turning the keyswitch to the ON position will check
the SCR module. the indicator lights on the control panel. All the
SCR Temperature Sensor – The sensor monitors indicator lights will be illuminated for 2 seconds after
the gas temperature entering the SCR. the keyswitch is operated. Replace suspect bulbs
immediately.
Ammonia Sensor – The sensor monitors the
concentration of ammonia within the exhaust system Refer to Troubleshooting for more information.
after the CEM.
i06725985
The temperature sensor before DOC, NOx sensor,
SCR temperature sensor, and ammonia sensor all
connect with the engine ECM. If the signal from these Selective Catalytic Reduction
sensors is out of the set range, the ECM will trigger
an alarm for the operator.
Warning System
DOC, SCR, and DPF System
The Selective Catalytic Reduction (SCR) system is a
Temperature Sensor before DOC – This sensor system used to reduce NOx emissions from the
monitors the gas temperature as the gas enters the engine. Diesel Exhaust Fluid (DEF) is pumped from
DOC the DEF tank and is sprayed into the exhaust stream.
The DEF reductant is stored on the catalyst and
DPF Temperature Sensor – The temperature reduces NOx, leaving nitrogen gas and water vapor.
sensor monitors the temperature within the DPF.
NOTICE
Soot Sensor Control – The soot sensor control unit Stopping the engine immediately after the engine has
monitors the amount of soot within the DPF.
been working under load can result in overheating of
NOx Sensor – Two NOx sensors monitor the NOx DEF system components.
concentration within the exhaust gas before and after
the SCR module. Refer to the Operation and Maintenance Manual,
“Engine Stopping” procedure to allow the engine to
SCR Temperature Sensor – The sensor monitors cool and to prevent excessive temperatures in the
the gas temperature entering the SCR. turbocharger housing and the DEF injector.
The temperature sensor before DOC, DPF
temperature sensor, soot sensor, NOx sensor, SCR
temperature sensor, and ammonia sensor all NOTICE
Allow the engine to perform a DEF purge of the DEF
connected to the ECM. If the signal from these system before you turn the battery disconnect switch
sensors is out of the set range, the ECM will trigger to OFF. Disconnecting the battery power too soon
an alarm for the operator. may prevent purging of the DEF lines after the engine
is shutdown. Refer to this Operation and Mainte-
Diesel Exhaust Fluid (DEF) System nance Manual, “Battery Disconnect Switch” for more
Control information.
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 41
Operation Section
Selective Catalytic Reduction Warning System
The DEF level gauge will only give an accurate • Inducement Categories The Inducements are
reading with the application on level ground. separated into categories. DEF Levels have
inducement fault codes separate from the other
inducement categories. DEF level inducements
are based on the DEF level, the other inducement
categories are based on escalating time. The
escalating time inducements will always have an
associated fault code along with the inducement
fault code. The associated fault is the root cause.
The escalating time inducement fault code is just
an indicator of what level of inducement the
engine is in. The escalating time inducement fault
code also indicates how much time remains until
the next level of inducement. There are three
inducement categories that will trigger an
escalating time inducement fault code.
• Self-correct Fault condition no longer exists. An • At Level 3 the emission malfunction lamp will flash
active fault code will no longer be active. and the stop lamp will activate.
• Notification Action taken by the system to alert • At Level 3 the engine may shut down or operate at
the operator of pending Inducement. 1000 Revolutions Per Minute (RPM).
• Inducement Engine derates, vehicle speed • At Level 3 cycling the keyswitch will give 20
limits, or other actions intended to prompt the minutes override at full power, before the
operator to repair or maintain the emission control shutdown or idle is triggered. The emission
system. malfunction lamp will continue to flash.
This document has been printed from SPI2. NOT FOR RESALE
42 SEBU9063-03
Operation Section
Selective Catalytic Reduction Warning System
Inducement Time None 2.5 Hours 70 minutes 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat occurrence inducement time will be triggered.
The override can only be used once
Inducement Time None 5 minutes 5 minutes 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None 75 Percent torque
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will be
on solid
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.
Table 4
World-Wide Reduced Performance Setting
Inducement Time None 10 Hours 10 Hours 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat occurrence inducement time will be triggered.
The override can only be used once
Inducement Time None None 2 Hours 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None 75 Percent of torque
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will be
on solid
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.
Table 5
World-Wide Reduced Performance Setting
(continued)
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 43
Operation Section
Selective Catalytic Reduction Warning System
(Table 5, contd)
Inducement Time None 36 Hours 64 Hours 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat occurrence inducement time will be triggered.
The override can only be used once
Inducement Time None None 5 Hours 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None 75 Percent of torque
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will be
on solid
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.
This document has been printed from SPI2. NOT FOR RESALE
44 SEBU9063-03
Operation Section
Selective Catalytic Reduction Warning System
Inducement Time None 2.5 Hours 70 minutes 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat inducement time will be triggered.
The override can only be used once.
Inducement Time None 5 minutes 5 minutes 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None None
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will
activate
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.
Table 7
World-Wide Reduced Time Setting
Inducement Time None 5 Hours 5 Hours 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat inducement time will be triggered.
The override can only be used once.
Inducement Time None None 1 Hour 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None None
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will
activate
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.
Table 8
World-Wide Reduced Time Setting
(continued)
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 45
Operation Section
Selective Catalytic Reduction Warning System
(Table 8, contd)
Inducement Time None 18 Hours 18 Hours 50 Percent torque Cycling the keyswitch
First Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then
the repeat inducement time will be triggered.
The override can only be used once.
Inducement Time None None 108 Minutes 50 Percent torque Cycling the keyswitch
Repeat Occurrence Shut down or idle will give 20 minutes
Until fault heals of full power
Inducement None None None
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will
activate
Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.
Inducement Trigger Above 20 percent Below 20 percent Below 14 percent 3.5 Percent reading A small quantity of
DEF will remain in the
DEF tank. This DEF
will only be used to
cool the DEF injector.
The DEF gauge will
show empty
Notification None Low-level lamp Low-level lamp Low-level lamp Low-level lamp
illuminated illuminated illuminated illuminated
Emission malfunction Emission malfunction Emission malfunction
lamp on solid lamp flashing lamp flashing
Stop lamp on solid
This document has been printed from SPI2. NOT FOR RESALE
46 SEBU9063-03
Operation Section
Battery Disconnect Switch
Table 10
World-Wide DEF Level Option 2
Inducement Trigger Above 20 percent Below 20 percent Below 14 percent 8 Percent reading 3.5 Percent reading
Notification None Low-level lamp Low-level lamp Low-level lamp Low-level lamp
illuminated illuminated illuminated illuminated
Emission malfunction Emission malfunction Emission malfunction
lamp on solid lamp flashing lamp flashing
Stop lamp on solid
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 47
Operation Section
Gauges and Indicators
• The indicator lamps can be used to identify active Tachometer – This gauge indicates
diagnostic codes. This system is activated by engine speed (rpm). When the throttle
pressing the Flash Code button. control lever is moved to the full throttle
position without load, the engine is running at
Refer to the Troubleshooting Guide, “Indicator high idle. The engine is running at the full load
Lamps” for further information. rpm when the throttle control lever is at the full
throttle position with maximum rated load.
NOTICE
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP NOTICE
the engine. Engine damage can result. Operation at speeds exceeding high idle rpm should
be kept to a minimum. Overspeeding can result in
serious damage to the engine.
Engine Oil Pressure – The oil pressure
should be greatest after a cold engine is
started. The typical engine oil pressure Ammeter – This gauge indicates the
with SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) amount of charge or discharge in the
at rated rpm. battery charging circuit. Operation of
the indicator should be to the “ +”” side of “ 0””
A lower oil pressure is normal at low idle. If the (zero).
engine speed and Load are stable and the gauge
reading changes, perform the following procedure: Fuel Level – This gauge indicates the
fuel level in the fuel tank. The fuel level
1. Remove the load. gauge operates when the “ START/STOP””
switch is in the “ on”” position.
2. Stop the engine.
3. Check and maintain the oil level. Service Hour Meter – The gauge
indicates total operating hours of the
Jacket Water Coolant Temperature – engine.
Typical temperature range is 82° to 94°C
(179.6° to 201.2°F). This temperature Low Level DEF – The gauge indicates
range will vary according to engine load and the the amount of DEF in the tank. Level
ambient temperature. ground is required for correct operation
of the gauge.
A 100 kPa (14.5 psi) radiator cap must be installed
on the cooling system. The maximum temperature for Indicator Lamps
the cooling system is 108° C (226.4° F). This
temperature is measured at the outlet for the water There are four indicator lamps that are available.
temperature regulator. The engine coolant
temperature is regulated by the engine sensors and • Shutdown Lamp
the engine ECM. This programming cannot be
altered. An engine derate can occur if the maximum • Warning Lamp
engine coolant temperature is exceeded.
• Wait to Start Lamp
If the engine is operating above the normal range,
reduce the engine load. If high coolant temperatures • Low Oil Pressure Lamp
are a frequent event, perform the following
procedures: For information, refer to this manual, “Monitoring
System (Table for the Indicator Lamps)” for the
1. Reduce the load and the engine rpm. sequence of operation of the shutdown lamp and the
2. Determine if the engine must be shut down warning lamp.
immediately or if the engine can be cooled by The function of the wait to start lamp is automatically
reducing the load. controlled at engine start-up.
3. Inspect the cooling system for leaks. If necessary, The function of the low oil pressure lamp is controlled
consult your Perkins distributor for assistance. by the engine ECM. If low oil pressure is detected,
the lamp will be illuminated. The reason for the
illumination of the low-pressure lamp should be
investigated immediately.
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48 SEBU9063-03
Operation Section
Monitoring System
All lamps will illuminate for 2 seconds in order to Note: The wait to disconnect lamp will not be
check that the lamps are functioning when the checked at key on. The wait to disconnect lamp will
keyswitch is turned to the ON position. If any of the illuminate at key on.
lamps stay illuminated, the reason for illumination
should be investigated immediately. i05194981
• Oil pressure
• Intake temperature
• Intake pressure
• Atmospheric pressure
• Fuel temperature
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SEBU9063-03 49
Operation Section
Overspeed
Table 11
Indicator Lamp Table
Shutdown
Warning Action Indi-
Lamp cator Lamp Lamp State Description of the Indication Engine Status
On On Lamp Check When the keyswitch is moved to the ON po- The keyswitch is in the ON position but the en-
sition, the lamps come on for 2 seconds and gine has not yet been cranked.
the lamps will then go off.
If any of the indicators will not illuminate during indicator check, the fault must be investigated immediately
If any Indicators stay illuminated or flash, the fault must be investigated immediately.
Off Off No Faults With the engine in operation, there are no The engine is operating with no detected
active warnings, diagnostic codes, or event faults.
codes.
On Solid Off Warning Level 1 warning The engine is operating normally but there is
one or more faults with the electronic manage-
ment system for the engine.
Flashing Off Warning Level 2 warning The engine continues to be operated, but the
level of importance of the warning has
increased.
Depending on the particular fault and the se-
verity the engine may be de-rated.
The engine could be damaged if continued to
be operated.
Flashing On Engine Shutdown Level 3 warning The engine is either shutdown or an engine
If both the warning lamp and the shutdown shutdown is imminent. One or more monitored
lamp are in operation, this issue indicates engine parameters have exceeded the limit for
one of the following conditions. an engine shutdown. This pattern of lamps can
be caused by the detection of a serious active
1. One or more of the shutdown values for diagnostic code.
the engine protection strategy has been
exceeded. Contact your Perkins dealer or your Perkins
distributor.
2. A serious active diagnostic code has
been detected.
This document has been printed from SPI2. NOT FOR RESALE
50 SEBU9063-03
Operation Section
Sensors and Electrical Components
i05769077
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 51
Operation Section
Sensors and Electrical Components
Engine Views
Illustration 39 g03419999
Typical example
(1) Coolant Temperature Sensor (6) Atmospheric Pressure Sensor (10) Fuel Temperature Sensor
(2) Fuel Pressure Sensor (Fuel Rail (Barometric Pressure Sensor) (11) Fuel Metering Solenoid for the High
Pressure Sensor) (7) Priming/ Transfer pump Pressure Fuel Pump
(3) Intake Manifold Air Temperature Sensor (8) Primary Speed/Timing sensor
(4) Intake Manifold Pressure Sensor (Crankshaft Position Sensor)
(5) Electronic Control Module (ECM) (9) Oil Pressure Sensor
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52 SEBU9063-03
Operation Section
Sensors and Electrical Components
Illustration 40 g03420017
Typical example
(12) Wastegate Regulator (14) Control Valve for the NRS (16) Differential Pressure Sensor for the
(13) Inlet Pressure Sensor for the NOx (15) Temperature Sensor for the NRS NRS
Reduction System (NRS)
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 53
Operation Section
Sensors and Electrical Components
Illustration 41 g03420076
Typical example
(17) Alternator (21) Low Oil Level Switch (if Equipped) (24) Secondary Speed/Timing Sensor
(18) Starter Solenoid (22) Inlet Air Temperature Sensor (Camshaft Position Sensor)
(19) Starting Motor (23) Water in Fuel Switch (25) Back Pressure Valve
(20) Starter Relay
This document has been printed from SPI2. NOT FOR RESALE
54 SEBU9063-03
Operation Section
Sensors and Electrical Components
Illustration 42 g02413838
Typical example
(1) Coolant Temperature Sensor (3) Intake Manifold Air Temperature Sensor
(2) Fuel Pressure Sensor (Fuel Rail (4) Intake Manifold Pressure Sensor
Pressure Sensor) (5) Electronic Control Module (ECM)
Illustration 43 g03420558
Typical example
(6) Atmospheric Pressure Sensor (8) Primary Speed/Timing sensor (10) Fuel Temperature Sensor
(Barometric Pressure Sensor) (Crankshaft Position Sensor) (11) Fuel Metering Solenoid for the High
(7) Priming/ Transfer pump (9) Oil Pressure Sensor Pressure Fuel Pump
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 55
Operation Section
Sensors and Electrical Components
Illustration 44 g03421140
Typical example
(12) Wastegate Regulator (14) Control Valve for the NRS (16) Differential Pressure Sensor for the
(13) Inlet Pressure Sensor for the NOx (15) Temperature Sensor for the NRS NRS
Reduction System (NRS)
Illustration 45 g03421147
Typical example
(17) Alternator (19) Starting Motor (21) Low Oil Level Switch (if Equipped)
(18) Starter Solenoid (20) Starter Relay
This document has been printed from SPI2. NOT FOR RESALE
56 SEBU9063-03
Operation Section
Sensors and Electrical Components
Illustration 46 g03421154
Typical example
(22) Inlet Air Temperature Sensor (24) Secondary Speed/Timing Sensor (25) Back Pressure Valve
(23) Water in Fuel Switch (Camshaft Position Sensor)
Aftertreatment Views
• DOC Diesel Oxidation Catalyst
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 57
Operation Section
Sensors and Electrical Components
Illustration 47 g03421173
Typical example
(1) SCR Temperature Sensor (3) DEF Injector
(2) Identification Module (4) DOC Temperature Sensor
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58 SEBU9063-03
Operation Section
Sensors and Electrical Components
Illustration 48 g03713372
Typical example
(1) SCR Temperature Sensor (4) DOC Temperature Sensor (7) DEF Injector
(2) Soot Sensor Connection (5) Identification Module (8) NOx Sensor location
(3) DPF Temperature Sensor (6) Soot Sensor Connection
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 59
Operation Section
Sensors and Electrical Components
Illustration 49 g03659936
Typical example
(1) DEF Pump and electronic unit (3) DEF Tank level and Temperature Sensor (5) Ammonia Sensor and Control
(2) Coolant Diverter Valve (4) NOx Sensors (6) Heated DEF Line
This document has been printed from SPI2. NOT FOR RESALE
60 SEBU9063-03
Operation Section
Engine Diagnostics
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SEBU9063-03 61
Operation Section
Engine Operation with Intermittent Diagnostic Codes
i05798673
Configuration Parameters
(continued)
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62 SEBU9063-03
Operation Section
Configuration Parameters
Rating Number
IVS Channel 1
IVS Channel 2
Continuous Position Throttle Configuration 1
Throttle Arbitration
Equipment ID
(continued)
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 63
Operation Section
Configuration Parameters
Air Shutoff
Throttle Lock Feature Installation Status
PTO Mode
Throttle Lock Engine Set Speed #1
Fan
Engine Fan Control
Fan Temperatures
(continued)
This document has been printed from SPI2. NOT FOR RESALE
64 SEBU9063-03
Operation Section
Configuration Parameters
Engine Cooling Fan Minimum Air Flow Charge Air Cooler Outlet
Temperature
Other Parameters
Maintenance Indicator Mode
Maintenance Level 1 Cycle Interval Hours
TSC 1 Droop %
(continued)
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 65
Operation Section
Configuration Parameters
PM1 Interval
Engine Oil Level Sensor Installation Status
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66 SEBU9063-03
Operation Section
Engine Starting
Perform the required daily maintenance and other Do not use aerosol types of starting aids such as
periodic maintenance before the engine is started. ether. Such use could result in an explosion and
Inspect the engine compartment. This inspection can personal injury.
help prevent major repairs at a later date. Refer to
the Operation and Maintenance Manual, The ability to start the engine will be improved at
“Maintenance Interval Schedule” for more temperatures below −18 °C (0 °F) from the use of a
information. jacket water heater or extra battery capacity.
• Ensure that the engine has an adequate fuel The following items provide a means of minimizing
supply. starting problems and fuel problems in cold weather:
Engine oil pan heaters, jacket water heaters, fuel
• Ensure that the engine has an adequate diesel heaters and fuel line insulation.
exhaust fluid supply Use the procedure that follows for cold weather
• Open the fuel supply valve (if equipped). starting.
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 67
Operation Section
Starting the Engine
5. Repeat step 2 through step 4 if the engine fails to Note: The operating period of the warning light for
start. the glow plugs will change due to the temperature of
the engine.
Note: After starting, the engine may be held at low
speed for a duration between 1 and 25 seconds to
NOTICE
allow engine systems to stabilize. The duration will Do not engage the starting motor when flywheel is
depend on ambient temperature, time since last run turning. Do not start the engine under load.
and other factors. The glow plug warning lamp will
flash in order to indicate that the engine is been held If the engine fails to start within 30 seconds, release
at low speed. the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
6. The engine should not be raced in order to speed start the engine again.
up the warm-up process. Allow the engine to idle
for 3 to 5 minutes, or allow the engine to idle until 4. Allow the keyswitch to return to the RUN position
the water temperature indicator begins to rise. after the engine starts.
When idling after the engine has started in cold
weather, increase the engine rpm from 1000 to 5. Repeat step 2 through step 4 if the engine fails to
1200 rpm. This operation will warm up the engine start.
more quickly. 6. After starting, the engine may be held at low speed
7. Operate the engine at low load until all systems for a duration between 1 and 25 seconds to allow
reach operating temperature. Check the gauges engine systems to stabilize. The duration will
during the warm-up period. depend on ambient temperature, time since last
run and other factors. The glow plug warning light
Following a cold start white smoke can be seen from will flash in order to indicate that the engine is
the tailpipe. This smoke is normal and caused by been held at low speed.
condensation leaving the exhaust system after
warming up. The white smoke should clear following
i06092747
working of the engine.
i05354322
Starting with Jump Start
Cables
Starting the Engine
(Do Not Use This Procedure in
Hazardous Locations that have
Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will Explosive Atmospheres)
control the engine speed during start-up.
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68 SEBU9063-03
Operation Section
After Starting Engine
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SEBU9063-03 69
Operation Section
Engine Operation
Gauge readings should be observed and the data During operation of the back pressure valve, trace
should be recorded frequently whilst the engine is amounts of exhaust gas may escape from the
operating. Comparing the data over time will help to connections in the exhaust system.
determine normal readings for each gauge.
Comparing data over time will also help detect Elevated Idle for Aftertreatment
abnormal operating developments. Significant
changes in the readings should be investigated. Continuous low load operation may lead to the
elevation of engine low idle speed to 1200
If a Diesel Particulate Filter (DPF) equipped Revolutions Per Minute (RPM). The elevation of
aftertreatment system are installed, avoid excess engine low idle speed is part of the aftertreatment
idling. Excessive idling causes soot loading of the management. The engine will only elevate low idle
DPF. Also, excessive idling will create carbon buildup when required and safety interlocks are in place. The
and engine slobber. These issues are harmful to the engine can continue to be operated as normal.
engine. Operating the engine for longer periods at higher
load will reduce the use of this elevated idle mode.
Reduction of Particulate Emissions Constant speed engines and engines with an idle
speed at or above 1200 RPM will not require the
Two different types of aftertreatment systems are increase in idle speed.
available.
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70 SEBU9063-03
Operation Section
Fuel Conservation Practices
Interrupted starts put excessive stress on the drive • Ensure that the turbocharger is operating
train. Interrupted starts also waste fuel. To get the correctly. For more information refer to this
driven equipment in motion, engage the clutch Operation and Maintenance Manual ,
smoothly with no load on the equipment. This “Turbocharger - Inspect”
method should produce a start that is smooth and
easy. The engine rpm should not increase and the • Maintain a good electrical system.
clutch should not slip.
One faulty battery cell will overwork the alternator.
3. Ensure that the ranges of the gauges are normal This fault will consume excess power and excess
when the engine is operating at one-half of the fuel.
rated rpm. Ensure that all gauges operate
properly. • The belt should be in good condition. Refer to the
Systems Operation, Testing and Adjusting, “V-Belt
4. Increase the engine rpm to the rated rpm. Always Test” for further information.
increase the engine rpm to the rated rpm before
the load is applied. • Ensure that all of the connections of the hoses are
tight. The connections should not leak.
5. Apply the load. Begin operating the engine at low
load. Check the gauges and equipment for proper • Ensure that the driven equipment is in good
operation. After normal oil pressure is reached and working order.
the temperature gauge begins to move, the engine
• Cold engines consume excess fuel. Utilize heat
may be operated at full load. Check the gauges from the jacket water system and the exhaust
and equipment frequently when the engine is system, when possible. Keep cooling system
operated under load. components clean and keep cooling system
components in good repair. Never operate the
Extended operation at low idle or at reduced load
may cause increased oil consumption and carbon engine without water temperature regulators. All of
buildup in the cylinders. This carbon buildup these items will help maintain operating
results in a loss of power and/or poor temperatures.
performance.
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Operation Section
Cold Weather Operation
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Operation Section
Cold Weather Operation
• For jump starting with cables in cold weather, refer While the engine is idling, the application of a light
to the Operation and Maintenance Manual, load (parasitic load) will assist in achieving the
“Starting with Jump Start Cables.” for instructions. minimum operating temperature. The minimum
operating temperature is 80° C (176° F).
Viscosity of the Engine Lubrication
Oil Recommendations for Coolant
Warm Up
Correct engine oil viscosity is essential. Oil viscosity
affects lubrication properties and wear protection that Warm up an engine that has cooled below normal
the oil provides for the engine. Refer to this Operation operating temperatures due to inactivity. This warm
and Maintenance Manual, “Fluid Recommendations” -up should be performed before the engine is
for the recommended viscosity of oil. returned to full operation. During operation in very
cold temperature conditions, damage to engine valve
At temperatures below −10° C (14° F) damage to mechanisms can result from engine operation for
engine components can occur if the engine is short intervals. This damage can happen if the
allowed to operate at high load and speed engine is started and the engine is stopped many
immediately after starting. times without being operated in order to warm up
completely.
Recommendations for the Coolant
When the engine is operated below normal operating
Provide cooling system protection for the lowest temperatures, fuel and oil are not burned completely
expected outside temperature. Refer to this in the combustion chamber. This fuel and oil causes
Operation and Maintenance Manual, “Fluid soft carbon deposits to form on the valve stems.
Recommendations” for the recommended coolant Generally, the deposits do not cause problems and
mixture. the deposits are burned off during operation at
normal engine operating temperatures.
In cold weather, check the coolant often for the
correct glycol concentration in order to ensure When starting and stopping an engine many times
adequate freeze protection. without being operated in order to warm up
completely, the carbon deposits become thicker. This
Engine Block Heaters starting and stopping can cause the following
problems:
Engine block heaters (if equipped) heat the engine
jacket water that surrounds the combustion • Free operation of the valves is prevented.
chambers. This heat provides the following functions:
• Valves become stuck.
• Startability is improved.
• Pushrods may become bent.
• Warm up time is reduced.
• Other damage to valve train components can
An electric block heater can be activated once the result.
engine is stopped. A block heater can be 110 V dc or
240 V dc. The output can be 750/1000W. Consult For these reasons, when the engine is started, the
your Perkins dealer or your Perkins distributor for engine must be operated until the coolant
more information. temperature is 80° C (176° F) minimum. Carbon
deposits on the valve stems will be kept at a
minimum. The free operation of the valves and the
Idling the Engine valve components will be maintained.
After starting the engine, the engine speed will be The engine must be warmed thoroughly in order to
governed for a maximum period of 25 seconds. keep other engine parts in better condition. The
When idling after the engine is started in cold service life of the engine will be generally extended.
weather, increase the engine rpm from 1000 to 1200 Lubrication will be improved. There will be less acid
rpm. This idling will warm up the engine more quickly. and less sludge in the oil. This condition will provide
Maintaining an elevated low idle speed for extended longer service life for the engine bearings, the piston
periods will be easier with the installation of a hand rings, and other parts. However, limit unnecessary
throttle. The engine should not be “raced” in order to idle time to 10 minutes in order to reduce wear and
speed up the warm-up process. unnecessary fuel consumption.
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Operation Section
Radiator Restrictions
The Water Temperature Regulator and Consult with your Perkins dealer or your Perkins
Insulated Heater Lines distributor for the recommended breather
components for operation from −25° to -40°C
The engine is equipped with a water temperature (−13° to -72.°F).
regulator. When the engine coolant is below the
correct operating temperature, jacket water circulates i05203509
through the engine cylinder block and into the engine
cylinder head. The coolant then returns to the Radiator Restrictions
cylinder block via an internal passage that bypasses
the valve of the coolant temperature regulator. This
return ensures that coolant flows around the engine
under cold operating conditions. The water Perkins discourages the use of airflow restriction
temperature regulator begins to open when the devices that are mounted in front of radiators. Airflow
engine jacket water has reached the correct restriction can cause the following conditions:
minimum operating temperature. As the jacket water
• High exhaust temperatures
coolant temperature rises above the minimum
operating temperature, the water temperature • Power loss
regulator opens further allowing more coolant
through the radiator to dissipate excess heat. • Excessive fan usage
The progressive opening of the water temperature • Reduction in fuel economy
regulator operates the progressive closing of the
bypass passage between the cylinder block and Reducing air flow over components will also affect
head. This action ensures maximum coolant flow to under hood temperatures. Reducing air flow can
the radiator in order to achieve maximum heat increase surface temperatures during an
dissipation.
aftertreatment regeneration and could affect
Note: Do not restrict the air flow. Restriction of the air component reliability.
flow can damage the fuel system. Perkins Reducing air flow can increase surface temperatures
discourages the use of all air flow restriction devices during an aftertreatment regeneration and could
such as radiator shutters. Restriction of the air flow affect component reliability.
can result in the following: high exhaust
temperatures, power loss, excessive fan usage and If an airflow restriction device must be used, the
reduction in fuel economy. device should have a permanent opening directly in
line with the fan hub. The device must have a 2
A cab heater is beneficial in very cold weather. The minimum opening dimension of at least 770 cm
feed from the engine and the return lines from the (120 in2).
cab should be insulated in order to reduce heat loss
to the outside air. A centered opening that is directly in line with the fan
hub is specified in order to prevent an interrupted
Recommendation for Crankcase airflow on the fan blades. Interrupted airflow on the
fan blades could cause a fan failure.
Breather Protection
Perkins recommends a warning device for the inlet
Crankcase ventilation gases contain a large quantity manifold temperature and/or the installation of an
of water vapor. This water vapor can freeze in cold inlet air temperature gauge. The warning device for
ambient conditions and can plug or damage the the inlet manifold temperature should be set at 75 °C
crankcase ventilation system. If the engine is (167 °F). The inlet manifold air temperature should
operated in temperatures below −25° C (−13° F), not exceed 75 °C (167 °F). Temperatures that
measures must be taken to prevent freezing and exceed this limit can cause power loss and potential
plugging of the breather system. Insulated hoses and engine damage.
a heated canister assembly should be installed.
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Operation Section
Fuel Related Components in Cold Weather
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Operation Section
Diesel Exhaust Fluid in Cold Weather
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Operation Section
Engine Stopping
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Operation Section
After Stopping Engine
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Maintenance Section
Refill Capacities
Maintenance Section
Refill Capacities
i05810113
Refill Capacities
Lubrication System
The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will
require additional oil. Refer to the Original Equipment
Manufacture (OEM) specifications for the capacity of
the auxiliary oil filter. Refer to the Operation and
Maintenance Manual, “Maintenance Section” for
more information on Lubricant Specifications.
Table 14
Engine
Refill Capacities
Maximum
Compartment or System Minimum (1) (2)
6L 14 L
Crankcase Oil Sump
(1.58 US gal) (3.69 US gal)
(1) The minimum value is the approximate capacity for the crank-
case oil sump (aluminum) which includes the standard factory
installed oil filters. Engines with auxiliary oil filters will require
additional oil. Refer to the OEM specifications for the capacity
of the auxiliary oil filter. The design of the oil pan can change
the oil capacity of the oil pan.
(2) Approximate capacity of the largest crankcase oil sump. Refer
to OEM for more information.
Cooling System
Refer to the OEM specifications for the External
System capacity. This capacity information will be
needed in order to determine the amount of coolant/
antifreeze that is required for the Total Cooling
System.
Table 15
Engine
Refill Capacities
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SEBU9063-03 79
Maintenance Section
Fluid Recommendations
Engine Oil
General Lubricant Information
Because of government regulations regarding the
Commercial Oils
certification of exhaust emissions from the engine,
the lubricant recommendations must be followed. NOTICE
Perkins require the use of the following specifica-
• API American Petroleum Institute tion of engine oil. Failure to use the appropriate
specification of engine oil will reduce the life of
• SAE Society Of Automotive Engineers Inc. your engine. Failure to use the appropriate speci-
fication of engine oil will also reduce the life of
• ACEA Association des Constructers your aftertreatment system.
European Automobiles.
Table 16
• ECF-3 Engine Crankcase Fluid
Classifications for the 1200 Series Industrial Engine
Licensing Oil Specification
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Maintenance Section
Fluid Recommendations
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Maintenance Section
Fluid Recommendations
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Maintenance Section
Fluid Recommendations
Care should be taken when dispensing DEF. Spills Materials NOT compatible with DEF solutions include
should be cleaned immediately. Machine or engine Aluminum, Magnesium, Zinc, Nickel coatings, Silver
surfaces should be wiped clean and rinsed with and Carbon steel and Solders containing any of the
water. Caution should be used when dispensing DEF above. Unexpected reactions may occur if DEF
near an engine that has recently been running. solutions come in contact with any non-compatible
Spilling DEF onto hot components will cause harmful material or unknown materials.
vapors.
i06288553
Storage
NOTICE
Perkins recommend that all DEF taken from storage If the engine is to be stored in, or shipped to an area
should be checked to ensure the DEF meets ISO with below freezing temperatures, the cooling system
standard 22241-1. must be either protected to the lowest outside tem-
perature or drained completely to prevent damage.
Materials compatibility
Non-metallic materials:
Many engine failures are related to the cooling
• Polyethylene system. The following problems are related to cooling
system failures: Overheating, leakage of the water
• Polypropylene pump and plugged radiators or heat exchangers.
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SEBU9063-03 83
Maintenance Section
Fluid Recommendations
Water is used in the cooling system in order to • Plugging of radiators, coolers, and small passages
transfer heat.
Distilled water or deionized water is
Glycol
recommended for use in engine cooling systems.
Glycol in the coolant helps to provide protection
DO NOT use the following types of water in cooling against the following conditions:
systems: Hard water, softened water that has been
conditioned with salt and sea water. • Boiling
Total Solids 340 mg/L Most conventional antifreezes use ethylene glycol.
Propylene glycol may also be used. In a 1:1 mixture
Acidity pH of 5.5 to 9.0 with water, ethylene and propylene glycol provide
similar protection against freezing and boiling. Refer
to Table 19 and refer to table 20 .
For a water analysis, consult one of the following Table 19
sources:
Ethylene Glycol
• Local water utility company
Concentration Freeze Protection
• Agricultural agent
50 Percent −36 °C (−33 °F)
• Independent laboratory 60 Percent −51 °C (−60 °F)
Additives
NOTICE
Additives help to protect the metal surfaces of the Do not use propylene glycol in concentrations that
cooling system. A lack of coolant additives or exceed 50 percent glycol because of the reduced
insufficient amounts of additives enable the following heat transfer capability of propylene glycol. Use ethyl-
conditions to occur: ene glycol in conditions that require additional protec-
tion against boiling or freezing.
• Corrosion
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84 SEBU9063-03
Maintenance Section
Fluid Recommendations
The following two coolants are used in Perkins diesel The anti-corrosion package for ELC is different from
engines: the anti-corrosion package for other coolants. ELC is
an ethylene glycol base coolant. However, ELC
Preferred – Perkins ELC contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrite. Perkins ELC has
Acceptable – A commercial heavy-duty antifreeze been formulated with the correct amount of these
additives in order to provide superior corrosion
that meets “ASTM D6210 ” specifications protection for all metals in engine cooling systems.
ELC is available in a premixed cooling solution with
NOTICE distilled water. ELC is a 1:1 mixture. The Premixed
The Perkins industrial engines must be operated ELC provides freeze protection to −36 °C (−33 °F).
with a 1:1 mixture of water and glycol. This con- The Premixed ELC is recommended for the initial fill
centration allows the NOx reduction system to of the cooling system. The Premixed ELC is also
operate correctly at high ambient temperatures. recommended for topping off the cooling system.
Containers of several sizes are available. Consult
NOTICE your Perkins distributor for the part numbers.
Do not use a commercial coolant/antifreeze that only
meets the ASTM D3306 specification. This type of ELC Cooling System Maintenance
coolant/antifreeze is made for light automotive
applications.
Correct additions to the Extended Life
Coolant
Perkins recommends a 1:1 mixture of water and
glycol. This mixture of water and glycol will provide
optimum heavy-duty performance as an antifreeze. NOTICE
This ratio may be increased to 1:2 water to glycol if Use only Perkins products for pre-mixed or concen-
extra freezing protection is required. trated coolants.
A mixture of SCA inhibitor and water is acceptable Mixing Extended Life Coolant with other products re-
but will not give the same level of corrosion, boiling duces the Extended Life Coolant service life. Failure
to follow the recommendations can reduce cooling
and, freezing protection as ELC. Perkins system components life unless appropriate corrective
recommends a 6 percent to 8 percent concentration action is performed.
of SCA in those cooling systems. Distilled water or
deionized water is preferred. In order to maintain the correct balance between the
Table 21 antifreeze and the additives, you must maintain the
Coolant Service Life
recommended concentration of ELC. Lowering the
proportion of antifreeze lowers the proportion of
Coolant Type Service Life (1) additive. Lowering the ability of the coolant to protect
the system will form pitting, from cavitation, from
6,000 Service Hours or Three erosion, and from deposits.
Perkins ELC
Years
Commercial Heavy-Duty Anti- NOTICE
freeze that meets “ASTM 3000 Service Hours or Two Year Do not use a conventional coolant to top-off a cooling
D6210” system that is filled with Extended Life Coolant
(ELC).
Commercial SCA inhibitor and
3000 Service Hours or One Year
Water Do not use standard supplemental coolant additive
(1) Use the interval that occurs first. The cooling system must also (SCA).
be flushed out at this time.
When using Perkins ELC, do not use standard SCA's
ELC or SCA filters.
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SEBU9063-03 85
Maintenance Section
Fluid Recommendations
Clean water is the only cleaning agent that is ELC Cooling System Contamination
required when ELC is drained from the cooling
system.
NOTICE
Before the cooling system is filled, the heater control Mixing ELC with other products reduces the effective-
(if equipped) must be set to the HOT position. Refer ness of the ELC and shortens the ELC service life.
to the OEM in order to set the heater control. After Use only Perkins Products for premixed or concen-
the cooling system is drained and the cooling system trate coolants. Failure to follow these recommenda-
is refilled, operate the engine until the coolant level tions can result in shortened cooling system
reaches the normal operating temperature and until component life.
the coolant level stabilizes. As needed, add the
coolant mixture in order to fill the system to the ELC cooling systems can withstand contamination to
specified level. 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
Changing to Perkins ELC the following procedures:
To change from heavy-duty antifreeze to the Perkins • Drain the cooling system into a suitable container.
ELC, perform the following steps: Dispose of the coolant according to local
regulations. Flush the system with a 5 to 10
NOTICE percent solution of Perkins ELC. Fill the system
Care must be taken to ensure that all fluids are con- with the Perkins ELC.
tained during performance of inspection, mainte-
nance, testing, adjusting and the repair of the • Drain a portion of the cooling system into a
product. Be prepared to collect the fluid with suitable suitable container according to local regulations.
containers before opening any compartment or disas-
Then, fill the cooling system with premixed ELC.
sembling any component containing fluids.
This procedure should lower the contamination to
Dispose of all fluids according to local regulations less than 10 percent.
and mandates.
• Maintain the system as a conventional Heavy-
Duty Coolant. Treat the system with an SCA.
1. Drain the coolant into a suitable container. Change the coolant at the interval that is
recommended for the conventional Heavy-Duty
2. Dispose of the coolant according to local Coolant.
regulations.
3. Fill the cooling system with a 33 percent solution of Commercial Heavy-Duty Antifreeze and
Perkins ELC and operate the engine, ensure that SCA
the thermostat opens. Stop the engine and allow
the engine to cool. Drain the coolant. NOTICE
Commercial Heavy-Duty Coolant which contains
Note: Use distilled or deionized water in the solution. Amine as part of the corrosion protection system
must not be used.
4. Again, fill the cooling system with a 33 percent
solution of Perkins ELC and operate the engine
ensure that the thermostat opens. Stop the engine NOTICE
and allow to cool. Never operate an engine without water temperature
regulators in the cooling system. Water temperature
5. Drain the drain the cooling system. regulators help to maintain the engine coolant at the
correct operating temperature. Cooling system prob-
NOTICE lems can develop without water temperature
Incorrect or incomplete flushing of the cooling system regulators.
can result in damage to copper and other metal
components. Check the antifreeze (glycol concentration) in order
to ensure adequate protection against boiling or
freezing. Perkins recommends the use of a
6. Fill the cooling system with the Perkins Premixed refractometer for checking the glycol concentration. A
ELC. Operate the engine. Ensure that all coolant hydrometer should not be used.
valves open then stop the engine. When cool
check the coolant level. Perkins engine cooling systems should be tested at
500 hour intervals for the concentration of SCA.
Additions of SCA are based on the results of the test.
An SCA that is liquid may be needed at 500 hour
intervals.
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Maintenance Section
Fluid Recommendations
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Maintenance Section
General Fuel Information
General Information
NOTICE
Every attempt is made to provide accurate, up-to-
date information. By use of this document you agree
that Perkins Engines Company Limited is not respon-
sible for errors or omissions.
NOTICE
These recommendations are subject to change with-
out notice. Contact your local Perkins distributor for
the most up-to-date recommendations.
NOTICE
The footnotes are key part of the Perkins "Specifica-
tion for Distillate Diesel Fuel" Table. Read ALL of the
footnotes.
Table 26
"Perkins Specification for Distillate Diesel Fuel"
Cloud Point °C The cloud point must not “D2500” “ISO 3015”
exceed the lowest expected
ambient temperature.
(continued)
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Maintenance Section
General Fuel Information
Kinematic Viscosity (4) MM2/S (cSt) The viscosity of the fuel that “D445” “ISO 3405”
is delivered to the fuel injec-
tion pump. 1.4 minimum
and 4.5 maximum
Water and sediment % weight 0.05% maximum “D1796” “ISO 3734”
Gums and Resins (5) mg/100mL 10 mg per 100 mL “D381” “ISO 6246”
maximum
Lubricity correctedwear mm 0.52 maximum “D6079” “ISO 12156-1”
scar diameter at 60 °C
(140 °F). (6)
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Maintenance Section
General Fuel Information
NOTICE
Operating with fuels that do not meet the Perkins rec-
ommendations can cause the following effects: Start-
ing difficulty, reduced fuel filter service life, poor
combustion, deposits in the fuel injectors, signifi-
cantly reduce service life of the fuel system. Also, the
creation of deposits in the combustion chamber and
reduced service life of the engine.
NOTICE
The Perkins 1200 series of diesel engine must be op-
erated 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.
Illustration 52 g02157153
(continued)
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Maintenance Section
General Fuel Information
“ASTM D975 GRADE 1D S15” “North American Light Distillate Diesel fuel with less than 15 PPM sul-
fur level”
“ASTM D975 GRADE 2D S15” “North American Middle Distillate general-purpose Diesel fuel with less
than 15 PPM sulfur level”
“JIS K2204” “Japanese Diesel Fuel” Must meet the requirements that are stated in
the section “Lubricity”.
“BS 2869: 2010 CLASS A2 or EU 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 Distillate Diesel Fuel.
Viscosity Sulfur
Viscosity is the property of a liquid of offering The level of sulfur is governed by emissions
resistance to shear or flow. Viscosity decreases with legislations. Regional regulation, national
increasing temperature. This decrease in viscosity regulations, or international regulations can require a
follows a logarithmic relationship for normal fossil fuel with a specific sulfur limit. The sulfur content of
fuel. The common reference is to kinematic viscosity. the fuel and the fuel quality must comply with all
Kinematic viscosity is the quotient of the dynamic existing local regulations for emissions.
viscosity that is divided by the density. The
determination of kinematic viscosity is normally by Perkins 1200 series diesel engines have been
readings from gravity flow viscometers at standard designed to operate only with ULSD. By using the
temperatures. Refer to “ISO 3104” for the test test methods “ASTM D5453, or ISO 20846”, the
method. content of sulfur in ULSD fuel must be below 15 PPM
(mg/kg) or 0.0015% mass.
The viscosity of the fuel is significant because fuel
serves as a lubricant for the fuel system components. NOTICE
Fuel must have sufficient viscosity to lubricate the Use of diesel fuel with higher than 15 PPM sulphur
fuel system in both extremely cold temperatures and limit in these engines will harm or permanently dam-
extremely hot temperatures. If the kinematic viscosity age emissions control systems and/or shorten serv-
of the fuel is lower than “1.4 cSt” at the fuel injection ice interval.
pump, damage to the fuel injection pump can occur.
This damage can be excessive scuffing and seizure.
Low viscosity may lead to difficult hot restarting,
stalling, and loss of performance. High viscosity may
result in seizure of the pump.
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Maintenance Section
General Fuel Information
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Maintenance Section
General Fuel Information
Glycerides present in biodiesel fuel will also cause Biodiesel has poor oxidation stability, which can
fuel filters to become blocked more quickly. Therefore result in long-term problems in the storage of
the regular service interval should be reduced to 250 biodiesel. Biodiesel fuel should be used within 6
hours. months of manufacture. Equipment should not be
stored with the B20 biodiesel blends in the fuel
When biodiesel fuel is used, crank case oil and system for longer than 3 months.
aftertreatment systems may be influenced. This
influence is due to the chemical composition and Due to poor oxidation stability and other potential
characteristics of biodiesel fuel, such as density and issues, it is strongly recommended that engines with
volatility, and to chemical contaminants that can be limited operational time either not use B20 biodiesel
present in this fuel, such as alkali and alkaline metals blends or, whilst accepting some risk, limit biodiesel
(sodium, potassium, calcium, and magnesium). blend to a maximum of B5. Examples of applications
that should limit the use of biodiesel are the following:
• Crankcase oil fuel dilution can be higher when Standby Generator sets and certain emergency
biodiesel or biodiesel blends are used. This vehicles.
increased level of fuel dilution when using
biodiesel or biodiesel blends is related to the For standby generator sets and emergency vehicles
typically lower volatility of biodiesel. In-cylinder that cannot avoid use of biodiesel blends fuel quality
in the engine fuel tank must be sampled and checked
emissions control strategies utilized in many of the monthly. Test should include acid number
industrial latest engine designs may lead to a (EN14104), oxidation stability (EN 15751 commonly
higher level of biodiesel concentration in the know as the Rancimant test), and sediment
sump. The long-term effect of biodiesel (ISO12937). For standby generator sets oxidation
concentration in crankcase oil is unknown stability of biodiesel blend must be 20 hours or more
currently. as per EN 15751. If the test shows that the fuel has
degraded, fuel tank must be drained and engine
• Perkins recommend the use of oil analysis to flashed by running with the fresh high-quality diesel
check the quality of the engine oil if biodiesel fuel fuel.
is used. Ensure that the level of biodiesel in the
fuel is noted when the oil sample is taken. Perkins strongly recommended that seasonally
operated engines have the fuel systems, including
Performance Related Issues fuel tanks, flashed with conventional diesel fuel
before prolonged shutdown periods. An example of
Due to the lower energy content than the standard an application that should seasonally flush the fuel
distillate fuel B20 will cause a power loss in order of 2 system is a combine harvester.
to 4 percent. In addition, over time the power may
deteriorate further due to deposits in the fuel Microbial contamination and growth can cause
injectors. corrosion in the fuel system and premature plugging
of the fuel filter. Consult your supplier of fuel for
Biodiesel and biodiesel blends are known to cause assistance in selecting appropriate anti-microbial
an increase in fuel system deposits, most significant additive.
of which are deposits within the fuel injector. These
deposits can cause a loss in power due to restricted Water accelerates microbial contamination and
or modified fuel injection or cause other functional growth. When biodiesel is compared to distillate
issues associated with these deposits. fuels, water is naturally more likely to exist in the
biodiesel. Therefore check frequently and if
Note: Perkins T40-0012 Fuel Cleaner is most necessary, drain the water separator.
effective in cleaning and preventing the formation of Materials such as brass, bronze, copper, lead, tin,
deposits. Perkins Diesel Fuel Conditioner helps to and zinc accelerate the oxidation process of the
limit deposit issues by improving the stability of biodiesel fuel. The oxidation process can cause
biodiesel and biodiesel blends. For more information deposits formation therefore these materials must not
refer to “Perkins Diesel Fuel System Cleaner, and be used for fuel tanks and fuel lines.
Perkins”.
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SEBU9063-03 93
Maintenance Section
General Fuel Information
Synthetic diesel fuels are produced by gasification of When auxiliary devices, accessories, or consum-
various feedstock and then synthesis to liquid to ables (filters, additives) which are made by other
obtain paraffinic diesel fuel. Based on the feedstock manufacturers are used on Perkins products, the
used these fuels are commonly referred to as Perkins warranty is not affected simply because of
Biomass to liquid (BTL), Gas to liquid (GTL) and Coal such use.
to liquid (CTL). Hydrotreating of vegetable oils and However, failures that result from the installation
animal fats is another emerging process for or use of other manufacturers devices, accesso-
production of bio based diesel fuel called ries, or consumables are NOT Perkins defects.
Hydrotreated Vegetable Oil (HVO). Therefore, the defects are NOT covered under the
Perkins warranty.
BTL and HVO fuels are considered to be low carbon
fuels as they reduce carbon foot print compared to Supplemental diesel fuel additives are not generally
fossil fuels and are commonly referred to as recommended. This recommendation is due to
renewable fuels. These fuels must not be confused potential damage to the fuel system or the engine.
with biodiesel FAME which is fundamentally different Your fuel supplier or the fuel manufacturer will add
fuel and is discussed in a separate section in this the appropriate supplemental diesel fuel additives.
manual.
Perkins recognizes the fact that additives may be
These paraffinic fuels have virtually no sulphur or required in some special circumstances.
aromatics and have very high cetane numbers which
enable very clean burning and efficient engine Note: Some anti-corrosion additives can lead to
operation. Chemically these fuels are similar to diesel injector fouling, this fouling can cause the injector to
fuel derived form petroleum and are therefore operate incorrectly.
suitable to use in diesel engines as a replacement or
blend stock with conventional diesel fuel. To be Contact your fuel supplier for those circumstances
acceptable renewable and alternative fuels must when fuel additives are required. Your fuel supplier
meet latest edition of the paraffinic diesel fuel can recommend the appropriate fuel additive and the
specification “CENTS 15940”. The fuel should also correct level of treatment.
meet requirements described in table 26 , Perkins
Specification for Distillate Diesel Fuel, EN590, or Note: For the best results, your fuel supplier should
latest ASTM D975 specification. treat the fuel when additives are required. The
treated fuel must meet the requirements that are
Ensure that the fuel has got appropriate cold flow
properties (cloud point and CFPP) for the minimum stated in table 26 .
statistical ambient temperature the engine is Perkins Diesel Fuel System Cleaner
expected to see in the operation. The Fuel must also
meet lubricity requirements as specified in the
lubricity section of this “Operation and Maintenance Perkins T40-0012 Fuel Cleaner is the only fuel
Manual” Fluid Recommendations cleaner that is recommended by Perkins.
If biodiesel or biodiesel blends of fuel are to be used,
Fuel for Cold-Weather Operation Perkins require the use of Perkins fuel cleaner. The
use of the fuel is to remove deposits within the fuel
The European standard “EN590” contains climate system that is created with the use of biodiesel. For
dependant requirements and a range of options. The more information on the use of biodiesel and
options can be applied differently in each country. biodiesel blends refer to “Recommendation for
There are five classes that are given to arctic Biodiesel and Using B20”.
climates and severe winter climates. 0, 1, 2, 3 and 4.
Perkins fuel cleaner will remove deposits that can
Fuel that complies with “EN590” CLASS 4 can be form in the fuel system with the use of biodiesel and
used at temperatures as low as −44 °C (−47.2 °F). biodiesel blends. These deposits can create a loss of
Refer to “EN590” fora detailed discretion of the power and engine performance.
physical properties of the fuel.
Once the fuel cleaner has been added to the fuel, the
The diesel fuel “ASTM D975 1-D” used in the United deposits within the fuel system are removed after 30
States of America may be used in very cold hours of engine operation. For maximum results,
temperatures that are below −18 °C (−0.4 °F). 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.
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94 SEBU9063-03
Maintenance Section
General Fuel Information
Details instruction on the rate of which the fuel • Perkins recommends the use of bulk fuel filter /
cleaner must be use are on the container. coalescer units which clean the fuel of both
particulate contamination and water in a single
Note: Perkins fuel cleaner is compatible with existing pass.
and U.S. EPA Tier 4 nonroad certified diesel engine
emission control catalysts and particulate filters. • Ensure that you use Perkins Advanced Efficiency
Perkins fuel system cleaner contains less than 15 Fuel Filters. Change your fuel filters per
ppm of sulfur and is acceptable for use with ULSD recommended service requirements or as needed.
fuel.
• Drain your water separators daily.
Contamination Control • Drain your fuel tanks of sediment and water per
Recommendations for Fuels the Operation and Maintenance Manual
instructions.
Fuels of “ISO 18/16/13” cleanliness level or cleaner
as dispensed into the engine or application fuel tank • Install and maintain a properly designed bulk filter
should be used. This will reduce risk of power loss, / coalescer filtration system. Continuous bulk
fuel system failures, and related down time of filtration systems may be required to ensure that
engines. This cleanliness level is important for new dispensed fuel meets the cleanliness target.
fuel system designs such as common rail injection
systems and unit injectors. These fuels systems Consult your Perkins distributor for availability of
utilize higher fuel injection pressures and have tight bulk filtration products.
clearances between moving parts to meet required
stringent emissions regulations. Peak injection • Centrifugal filters may need to be used as a pre-
pressures in current fuel injection systems may filter with fuel that is severely contaminated with
exceed 2000 bar (29000 psi). Clearances in these gross amounts of water and/or large particulate
systems are less than 5 µm. As a result, particle contaminants. Centrifugal filters can effectively
contaminants as small as 4 µm can cause scoring remove large contaminants. Centrifugal filters may
and scratching of internal pump and injector surfaces not be able to remove the small abrasive particles
and of injector nozzles. required to achieve the recommended “ISO”
cleanliness level. Bulk filter / coalescers are
Water in the fuel causes cavitation, corrosion of fuel necessary as a final filter to achieve the
system parts, and provides an environment where recommended cleanliness level.
microbial growth in the fuel can flourish. Other
sources of fuel contamination are soaps, gels, or • Install desiccant type breathers of 4 µm or less
other compounds that may result from undesirable absolute efficiency with the ability to remove water
chemical interactions in the fuels, particularly in on bulk storage tanks.
ULSD. Gels and other compounds can also form in
biodiesel fuel at low temperatures or if biodiesel is • Follow proper practices of fuel transportation.
stored for extended periods. The best indication of Filtration from the storage tank to the application
microbial contamination, fuel additives, or cold
temperature gel is rapid filter plugging of bulk fuel promotes the delivery of clean fuel. Fuel filtration
filters or application fuel filters. can be installed at each transport stage to keep
the fuel clean.
To reduce downtime due to contamination, follow
these fuel maintenance guidelines. • Cover, protect, and ensure cleanliness of all
connection hoses, fittings, and dispensing
• Use high-quality fuels per recommended and nozzles.
required specifications
Consult your local Perkins distributor for additional
• Fill fuel tanks with fuels of “ISO 18/16/13” information on Perkins designed and produced
cleanliness level or cleaner, in particular for filtration products.
engines with common rail and unit injection
systems. When you refuel the tank, filter the fuel
through a 4 µm absolute filter (Beta 4 = 75 up to
200) to reach the recommended cleanliness level.
This filtration should be installed at the device that
dispenses the fuel to the fuel tank. In addition,
filtration at the dispensing point should remove
water to ensure that fuel is dispensed at 500 ppm
water or less.
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SEBU9063-03 95
Maintenance Section
Maintenance Recommendations
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding
Contact with high pressure fuel may cause fluid can cause damage to the drive train bearings, hy-
penetration and burn hazards. High pressure fuel draulic components, electrical components, and oth-
spray may cause a fire hazard. Failure to follow er components.
these inspection, maintenance and service in-
structions may cause personal injury or death. Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
The high pressure fuel lines are the fuel lines that are as possible to the weld. This will help reduce the pos-
between the high pressure fuel pump and the high sibility of damage.
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel Note: Perform the welding in areas that are free from
systems. explosive hazards.
This is because of the following differences:
1. Stop the engine. Turn the switched power to the
• The high pressure fuel lines are constantly OFF position.
charged with high pressure. 2. Ensure that the fuel supply to the engine is turned
• The internal pressures of the high pressure fuel off.
lines are higher than other types of fuel system. 3. Disconnect the negative battery cable from the
Before any service or repair is performed on the battery. If a battery disconnect switch is provided,
engine fuel lines, perform the following tasks: open the switch.
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96 SEBU9063-03
Maintenance Section
Welding on Engines with Electronic Controls
• ECM
• Sensors
• Relays
• Aftertreatment ID module
NOTICE
Do not use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.
Illustration 53 g01075639
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage any associated components.
(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
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SEBU9063-03 97
Maintenance Section
Severe Service Application
7. Use standard welding practices to weld the Quality of the air – The engine may be exposed to
materials. extended operation in an environment that is dirty or
dusty, unless the equipment is cleaned regularly.
i05196263
Mud, dirt, and dust can encase components.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals.
Severe Service Application
Buildup – Compounds, elements, corrosive
chemicals, and salt can damage some components.
Severe service is the application of an engine that Altitude – Problems can arise when the engine is
exceeds the current published standards for that operated at altitudes that are higher than the
engine. Perkins maintains standards for the following intended settings for that application. Necessary
engine parameters: adjustments should be made.
• Performance such as power range, speed range,
and fuel consumption
Incorrect Operating Procedures
• Fuel quality
• Extended operation at low idle
• Operational Altitude
• Frequent hot shutdowns
• Maintenance intervals
• Operating at excessive loads
• Oil selection and maintenance
• Operating at excessive speeds
• Coolant type and maintenance
• Operating outside the intended application
• Environmental qualities
• Installation
Incorrect Maintenance Procedures
• The temperature of the fluid in the engine • Extending the maintenance intervals
Refer to the standards for the engine or consult your • Failure to use recommended fuel, lubricants, and
Perkins dealer or your Perkins distributor in order to coolant/antifreeze
determine if the engine is operating within the defined
parameters.
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.
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.
Environmental Factors
Ambient temperatures – The engine may be
exposed to extended operation in extremely cold
environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
cold temperatures. Extremely hot intake air reduces
engine performance.
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98 SEBU9063-03
Maintenance Section
Maintenance Interval Schedule
Every Week
“ Hoses and Clamps - Inspect/Replace”. . . . . . . . 128
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SEBU9063-03 99
Maintenance Section
Maintenance Interval Schedule
Commissioning
“ Fan Clearance - Check” . . . . . . . . . . . . . . . . . . . 120
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100 SEBU9063-03
Maintenance Section
Aftercooler Core - Clean/Test
i01807350 i02322311
Aftercooler Core - Inspect 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
Note: Adjust the frequency of cleaning according to batteries should be kept warm because temperature
the effects of the operating environment. affects the cranking power. If the battery is too cold,
the battery will not crank the engine. When the
Inspect the aftercooler for these items: damaged fins, engine is not run for long periods of time or if the
corrosion, dirt, grease, insects, leaves, oil and other engine is run for short periods, the batteries may not
debris. Clean the aftercooler, if necessary. fully charge. A battery with a low charge will freeze
more easily than a battery with a full charge.
For air-to-air aftercoolers, use the same methods that
are used for cleaning radiators.
i02680137
Battery - Replace
After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine. Use
a light bulb behind the core in order to inspect the
core for cleanliness. Repeat the cleaning, if
necessary.
Batteries give off combustible gases which can
Inspect the fins for damage. Bent fins may be opened explode. A spark can cause the combustible
with a “comb”. gases to ignite. This can result in severe personal
injury or death.
Note: If parts of the aftercooler system are repaired
or replaced, a leak test is highly recommended. Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
Inspect these items for good condition: Welds, der to help prevent electrical arcs and/or sparks
mounting brackets, air lines, connections, clamps near batteries. Do not smoke when batteries are
serviced.
and seals. Make repairs, if necessary.
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SEBU9063-03 101
Maintenance Section
Battery Electrolyte Level - Check
The battery cables or the batteries should not be All lead-acid batteries contain sulfuric acid which
removed with the battery cover in place. The bat- can burn the skin and clothing. Always wear a
tery cover should be removed before any servic- face shield and protective clothing when working
ing is attempted. on or near batteries.
Battery Electrolyte Level - 1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position
Check and remove the key and all electrical loads.
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102 SEBU9063-03
Maintenance Section
Belt - Inspect
2. Disconnect the negative battery terminal. Ensure • Inspect the belt for cracks, splits, glazing, grease,
that the cable cannot contact the terminal. When displacement of the cord and evidence of fluid
four 12 V batteries are involved, 2 negative contamination.
connections must be disconnected. The belt must be replaced if the following conditions
3. Remove the positive connection. are present.
4. Clean all disconnected connection and battery • The belt has a crack in more than one rib.
terminals.
• More than one section of the belt is displaced in
5. Use a fine grade of sandpaper to clean the one rib of a maximum length of 50.8 mm (2 inch).
terminals and the cable clamps. Clean the items
To replace the belt, refer to Disassembly and
until the surfaces are bright or shiny. DO NOT Assembly, “Alternator Belt - Remove and Install”. If
remove material excessively. Excessive removal necessary, replace the belt tensioner. Refer to
of material can cause the clamps to fit incorrectly. Disassembly and Assembly, “Alternator Belt -
Coat the clamps and the terminals with a suitable Remove and Install” for the correct procedure.
silicone lubricant or petroleum jelly.
i05424329
6. Tape the cable connections in order to help
prevent accidental starting. Belt Tensioner - Check
7. Proceed with necessary system repairs.
8. In order to connect the battery, connect the
positive connection before the negative connector.
i05424335
Belt - Inspect
Illustration 55 g03423083
Typical example
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SEBU9063-03 103
Maintenance Section
Clean Emissions Module Support - Inspect
i05916407
Illustration 56 g03723522
Typical example
There are three mounts on the Clean Emissions • The oil has entered the cooling system and the
Modules (CEM) that must be inspected. coolant is contaminated.
1. Inspect mount (1) for wear or damage. • The fuel has entered the cooling system and the
2. Inspect mounts (2) for wear or damage, if wear or coolant is contaminated.
damage is found the mounts must be replaced.
NOTICE
3. Refer to the Disassembly and Assembly, “Support When any servicing or repair of the engine cooling
and Mounting (DEF) Remove and Install” for more system is performed, the procedure must be per-
information. formed with the engine on level ground. Level ground
will allow you to check accurately the coolant level.
A remote mounted (CEM) must also be inspected for This procedure will also help in avoiding the risk of in-
wear or damage. troducing an air lock into the coolant system.
i05676795
Note: Inspect the water pump and the water
Coolant (DEAC) - Change 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.
• DEAC Diesel Engine Antifreeze Coolant
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
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104 SEBU9063-03
Maintenance Section
Coolant (DEAC) - Change
NOTICE
Pressurized System: Hot coolant can cause seri- Do not fill the cooling system faster than 5 L
ous burns. To open the cooling system filler cap, (1.3 US gal) per minute to avoid air locks.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Cooling system air locks may result in engine
pressure cap slowly in order to relieve the damage.
pressure.
3. Fill the cooling system with clean water and install
1. Stop the engine and allow the engine to cool. the cooling system filler cap.
Loosen the cooling system filler cap slowly in 4. Start and run the engine at low idle for a minimum
order to relieve any pressure. Remove the cooling of 30 minutes. The coolant temperature should be
system filler cap. at least 82 °C (180 °F).
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on NOTICE
Improper or incomplete rinsing of the cooling system
Containing Fluid Spillage. can result in damage to copper and other metal
components.
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 signs of the
cleaning agent are gone.
Fill
Illustration 57 g03423123
Typical example NOTICE
Do not fill the cooling system faster than 5 L
2. Remove drain plug (1) on the engine. Also remove (1.3 US gal) per minute to avoid air locks.
the drain plug (2). Open the drain cock or remove Cooling system air locks may result in engine
the drain plug on the radiator. damage.
Allow the coolant to drain into a suitable container.
1. Fill the cooling system with the coolant/antifreeze.
3. Properly dispose of the drained material. Obey
Refer to this Operation and Maintenance Manual,
local regulations for the disposal of the material.
“Refill Capacities and Recommendations” topic
(Maintenance Section) for more information on
Flush cooling system specifications. Do not install the
cooling system filler cap.
1. Flush the cooling system with clean water and a
suitable cleaning agent in order to remove any
debris. Refer to your Perkins dealer or distributor
for suitable cleaning agents.
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SEBU9063-03 105
Maintenance Section
Coolant (ELC) - Change
NOTICE
Perkins ELC must be using with an extender in order
to achieve 12000 hours operation. For more informa-
tion on a suitable extender contact your Perkins
distributor.
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
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106 SEBU9063-03
Maintenance Section
Coolant Extender (ELC) - Add
For information regarding the disposal and the 2. Start and run the engine at low idle. Increase the
recycling of used coolant, consult your Perkins dealer engine rpm to high idle. Operate the engine in
or Perkins distributor. order to open the engine thermostat. An open
thermostat will allow any air in the system to be
Flush purged. Decrease the engine speed to low idle.
Stop the engine.
1. Flush the cooling system with distilled or deionized
water in order to remove any debris. 3. Maintain the coolant level at the maximum mark
that is correct for your application.
2. Install the connection hose. Clean the drain plugs
and install the drain plugs. Tighten the drain plugs 4. Clean the cooling system filler cap. Inspect the
securely. gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap is
NOTICE damaged, discard the old cooling system filler cap
Do not fill the cooling system faster than 5 L and install a new cooling system filler cap. If the
(1.3 US gal) per minute to avoid air locks. gasket that is on the cooling system filler cap is not
Cooling system air locks may result in engine damaged, pressure test the cooling system filler
damage. 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
3. Fill the cooling system with distilled or deionized does not retain the correct pressure, install a new
water. Install the cooling system filler cap. cooling system filler cap.
4. Start and run the engine at low idle until the 5. Start the engine. Inspect the cooling system for
temperature reaches 49 to 66 °C (120 to 150 °F). leaks and for proper operating temperature.
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in i05197396
order to relieve any pressure. Remove the cooling
system filler cap. Remove the connection hose Coolant Extender (ELC) - Add
and remove the cooling system drain plugs. Allow
the water to drain. Flush the cooling system with
clean water. Install the connection hose. In order for Perkins ELC to achieve 12000 hours an
extender must be added at 6000 hours. For a
6. The drain plug O rings on the engine block must be suitable extender, contact your Perkins dealer or
replaced. Clean the drain plugs and install new O Perkins distributor.
ring seal. Install the drain plugs and tighten to a
i05682210
torque of 35 N·m (25 lb ft).
Coolant Level - Check
Fill
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Pressurized System: Hot coolant can cause seri-
Cooling system air locks may result in engine ous burns. To open the cooling system filler cap,
damage. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
1. Fill the cooling system with Extended Life Coolant pressure.
(ELC). Refer to this Operation and Maintenance
Manual, “Refill Capacities ” topic (Maintenance Check the coolant level when the engine is stopped
and cool.
Section) for more information on cooling system
specifications. Do not install the cooling system
filler cap.
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SEBU9063-03 107
Maintenance Section
DEF Filler Screen - Clean
i05921440
NOTICE
When any servicing or repair of the engine cooling
system is performed, the procedure must be per- DEF Filler Screen - Clean
formed with the engine on level ground. This proce-
dure will allow you to check accurately the coolant
level. This procedure will also help in avoiding the risk
of introducing an air lock into the coolant system. NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
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.
Illustration 59 g02590196
Illustration 60 g03725939
Typical filler cap gaskets Typical example
3. Clean the cooling system filler cap and check the 1. Ensure that the area around cap on the Diesel
condition of the filler cap gaskets. Replace the Exhaust Fluid (DEF) tank is clean. Remove cap
cooling system filler cap if the filler cap gaskets are (1).
damaged. Reinstall the cooling system filler cap.
2. Using a suitable tool, press the tabs (2) in order to
4. Inspect the cooling system for leaks. release the tabs. With the tabs released remove
Note: The Diesel Exhaust Fluid (DEF) tank requires the filter screen (3) from DEF tank neck adapter
coolant flow around the tank. The Coolant Diverter (4).
Valve (CDV) will turn the flow on or off. If the coolant 3. The filter screen can be cleaned in clean water and
system has been filled with the CDV in the closed
position, coolant level will drop because of the dried using compressed air. Refer to this
opening of the CDV. The coolant flow will be diverted Operation and Maintenance Manual, “General
when the ambient temperature is approximately Hazard Information” for information on using
−5° C (23° F). compressed air.
4. If the filter screen cannot be cleaned or the filter
screen is damaged, then the filter screen must be
replaced.
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108 SEBU9063-03
Maintenance Section
DEF Manifold Filters - Replace
5. Install filter screen (3) into DEF tank neck adapter i06216651
(4). Press filter screen into neck adapter and
ensure that tabs (2) are located correctly. Install Diesel Exhaust Fluid - Fill
cap (1).
i05921489
Illustration 62 g03714036
Typical example
Replace the manifold filter (1). Refer to Disassembly Care should be taken when dispensing DEF. Spills
and Assembly, “Manifold (DEF Heater) - Remove and should be cleaned immediately. All surfaces should
Install” for more information. be wiped clean and rinsed with water.
DEF that has been split will crystallize when the
water within the liquid evaporates. Split DEF will
attack paint and metal. If DEF is split, wash the area
with water.
Caution should be used when dispensing DEF near
an engine that has recently been running. Spilling
DEF onto hot components may cause the release of
ammonia vapors. Do not breathe ammonia vapors.
Do not clean up any spills with bleach.
Ensure that the DEF tank is full before starting work.
1. Before filling the DEF tank, ensure that the DEF
lines have been purged. Purging of the DEF lines
will take place, after the engine has stopped. Only
after purging the DEF lines should the DEF tank
be filled. For more information on the time taken
for purging the DEF lines, refer to this Operation
and Maintenance Manual, “Battery Disconnect
Switch ”.
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SEBU9063-03 109
Maintenance Section
Diesel Exhaust Fluid Filter - Clean/Replace
i05952254
Illustration 63 g03700666
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110 SEBU9063-03
Maintenance Section
Diesel Exhaust Fluid Tank - Flush
i02151646
Illustration 64 g03676503
Typical example Driven Equipment - Check
If contamination of the Diesel Exhaust Fluid (DEF) is
suspected, the DEF tank (3) will need to be drained Refer to the OEM specifications for more information
and the DEF tank flushed. on the following maintenance recommendations for
1. Ensure that the purging of the DEF system has the driven equipment:
been completed. • Inspection
2. After the completion of the purging, Isolate the
• Adjustment
power, refer to this Operation and Maintenance
Manual, “Battery Disconnect Switch” for more • Lubrication
information.
• Other maintenance recommendations
Note: Ensure that the vessel that will be used is large
enough to collect the fluid to be drained. Perform any maintenance for the driven equipment
which is recommended by the OEM.
3. Position the vessel below the drain plug (4).
Remove the filler cap (1) Remove the drain plug
and allow the fluid to drain.
4. Remove the Manifold (DEF Heater) (2). Refer to
Disassembly and Assembly, “Manifold (DEF
Heater)-Remove and Install” after draining the
fluid.
5. If necessary, remove the DEF filler screen. For
more information, refer to this Operation and
Maintenance Manual, “DEF Filler Screen - Clean”.
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SEBU9063-03 111
Maintenance Section
Engine - Clean
i06709044 Aftertreatment
Engine - Clean 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.
i05207494
Personal injury or death can result from high
voltage. Engine Air Cleaner Element
Moisture can create paths of electrical (Dual Element) - Inspect/Clean/
conductivity.
Replace
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “ DO
NOT OPERATE”” .
NOTICE
Never run the engine without an air cleaner element
NOTICE installed. Never run the engine with a damaged air
Accumulated grease and oil on an engine is a fire cleaner element. Do not use air cleaner elements
hazard. Keep the engine clean. Remove debris and with damaged pleats, gaskets or seals. Dirt entering
fluid spills whenever a significant quantity accumu- the engine causes premature wear and damage to
lates on the engine. engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following NOTICE
benefits: Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
• Easy detection of fluid leaks
• Maximum heat transfer characteristics Servicing the Air Cleaner Elements
• Ease of maintenance
Note: The air filter system may not have been
Note: Caution must be used to prevent electrical provided by Perkins. The procedure that follows is for
components from being damaged by excessive water a typical air filter system. Refer to the OEM
when the engine is cleaned. Pressure washers and information for the correct procedure.
steam cleaners should not be directed at any If the air cleaner element becomes plugged, the air
electrical connectors or the junction of cables into the can split the material of the air cleaner element.
rear of the connectors. Avoid electrical components Unfiltered air will drastically accelerate internal
such as the alternator, the starter, and the ECM. engine wear. Refer to the OEM information for the
Protect the fuel injection pump from fluids to wash the correct air cleaner elements for your application.
engine.
• Check the precleaner (if equipped) and the dust
Ensure that care is taken that the safety labels, bowl daily for accumulation of dirt and debris.
emission label, and any information labels are not Remove any dirt and debris, as needed.
removed during engine cleaning.
• Operating in dirty conditions may require more
Ensure that care is taken that the safety labels, frequent service of the air cleaner element.
emission label, and all other information labels are
not removed during engine cleaning.
• The air cleaner element should be replaced at
least one time per year. This replacement should
be performed regardless of the number of
cleanings.
Replace the dirty air cleaner elements with clean air
cleaner elements. Before installation, the air cleaner
elements should be thoroughly checked for tears
and/or holes in the filter material. Inspect the gasket
or the seal of the air cleaner element for damage.
Maintain a supply of suitable air cleaner elements for
replacement purposes.
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112 SEBU9063-03
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
Dual Element Air Cleaners 7. Reset the air cleaner service indicator.
The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner
Cleaning the Primary Air Cleaner
element. Elements
The primary air cleaner element can be used up to Refer to the OEM information in order to determine
six times if the element is properly cleaned and the number of times that the primary filter element
properly inspected. The primary air cleaner element can be cleaned. When the primary air cleaner
should be replaced at least one time per year. This element is cleaned, check for rips or tears in the filter
replacement should be performed regardless of the material. The primary air cleaner element should be
number of cleanings. replaced at least one time per year. This replacement
should be performed regardless of the number of
The secondary air cleaner element is not serviceable. cleanings.
Refer to the OEM information for instructions in order
to replace the secondary air cleaner element.
NOTICE
When the engine is operating in environments that Do not tap or strike the air cleaner element.
are dusty or dirty, air cleaner elements may require Do not wash the primary air cleaner element.
more frequent replacement.
Use low pressure (207 kPa 30 psi maximum) pres-
surized air or vacuum cleaning to clean the primary
air cleaner element.
Take extreme care in order to avoid damage to the air
cleaner elements.
Do not use air cleaner elements that have damaged
pleats, gaskets, or seals.
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SEBU9063-03 113
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace
Illustration 67 g00281693
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114 SEBU9063-03
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Illustration 69 g00103777
Typical service indicator
Illustration 68 g00310664
Observe the service indicator. The air cleaner
(1) Air cleaner cover element should be cleaned or the air cleaner element
(2) Air filter element should be replaced when one of the following
(3) Air inlet
conditions occur:
1. Remove air cleaner cover (1) and remove air filter • The yellow diaphragm enters the red zone.
element (2).
• The red piston locks in the visible position.
2. Cover air inlet (3) with tape or a clean cloth so that
debris cannot enter the air inlet. Test the Service Indicator
3. Clean the inside of air cleaner cover (1). Clean the
Service indicators are important instruments.
body that holds the air cleaner element.
4. Inspect the replacement element for the following • Check for ease of resetting. The service indicator
items:damage, dirt and debris. should reset in less than three pushes.
5. Remove the seal from the opening of the air inlet. • Check the movement of the yellow core when the
engine is accelerated to the engine rated speed.
6. Install a clean, undamaged air filter element (2). The yellow core should latch at the greatest
vacuum that is attained.
7. Install air cleaner cover (1).
If the service indicator does not reset easily, or if the
8. Reset the air cleaner service indicator. yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
i02335405 service indicator will not reset, the hole for the service
indicator may be restricted.
Engine Air Cleaner Service
Indicator - Inspect
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SEBU9063-03 115
Maintenance Section
Engine Air Precleaner - Check/Clean
The service indicator may need to be replaced The crankcase breather is a very important
frequently in environments that are severely dusty. component in order to keep your engine emissions
compliant.
i02927289
• The filter element within the crankcase breather
must be serviced at the prescribed service
Engine Air Precleaner - Check/ interval.
Clean • The correct filter element must be installed before
the engine is operated.
i05926015
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116 SEBU9063-03
Maintenance Section
Engine Mounts - Inspect
2. Rotate the cap (1) counterclockwise into the 6. Install the cap (1). Rotate the cap by hand
unlocked position. Remove the cap from the body clockwise until the cap locks into the locked
of the breather (3). position C on the breather body.
3. Note the orientation of the filter element (2). 7. Remove the container.
Remove the filter element .
Check the System
Illustration 72 g01884135
(B) Alignment position
Note: The cut away from section (5) in the cap allows
access to the seal.
i02323089
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SEBU9063-03 117
Maintenance Section
Engine Oil Level - Check
i05300117 2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
Engine Oil Level - Check If an increase in the oil level is noticed, refer to
Troubleshooting, “Oil Contains Fuel”.
i01907674
1. Maintain the oil level between the mark (L) and the • Engine number
mark (H) on the engine oil dipstick. Do not fill the
• Service hours on the engine
crankcase above the “H” .
• The number of hours that have accumulated since
the last oil change
• The amount of oil that has been added since the
last oil change
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118 SEBU9063-03
Maintenance Section
Engine Oil and Filter - Change
Ensure that the container for the sample is clean and Drain the Engine Lubricating Oil
dry. Also ensure that the container for the sample is
clearly labelled. Note: Ensure that the vessel that will be used is large
enough to collect the waste oil.
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, well mixed oil After the engine has been run at the normal
sample. operating temperature, stop the engine. Use one of
To avoid contamination of the oil samples, the tools the following methods to drain the engine oil pan:
and the supplies that are used for obtaining oil
samples must be clean.
The sample can be checked for the following: the
quality of the oil, the existence of any coolant in the
oil, the existence of any ferrous metal particles in the
oil and the existence of any nonferrous metal
particles in the oil.
i05679393
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SEBU9063-03 119
Maintenance Section
Engine Oil and Filter - Change
Remove the container and disposal of the waste oil in Horizontal Oil Filter
accordance with local regulations.
Illustration 78 g02132333
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
Illustration 77 g02131364
nated. Contaminated oil can cause accelerated wear
to engine components.
2. Clean sealing surface (1).
5. Apply clean engine oil to O ring seal (3) for the new
3. Apply clean engine oil to O ring seal (2) for the new oil filter (4).
oil filter (3).
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.
4. Install the new oil filter (3). Spin on the oil filter until
the O ring contacts the sealing surface (2). Then
rotate the oil filter ¾ of a full turn. Remove the
container and disposal of the waste oil in
accordance with local regulations.
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120 SEBU9063-03
Maintenance Section
Fan Clearance - Check
6. Install the new oil filter. Spin on the oil filter (4) until 4. Remove the engine oil level gauge in order to
the O ring contacts the sealing surface (2). Then check the oil level. Maintain the oil level between
rotate the oil filter ¾ of a full turn. Remove the “L” and “H” marks on the engine oil level gauge.
container and disposal of the waste oil in Do not fill the crankcase above the “H” mark.
accordance with local regulations.
i05685634
Fill the Oil Pan
Fan Clearance - Check
1. Remove the oil filler cap. Refer to this Operation
and Maintenance Manual, “Fluid
Recommendations” for more information on Commissioning Information
suitable oils. Fill the oil pan with the correct
amount of new engine lubricating oil. Refer to this Fan tip clearance at commissioning must be set with
Operation and Maintenance Manual, “Refill the radiator empty.
Capacities” for more information on refill
capacities.
NOTICE
If equipped with an auxiliary oil filter system or a re-
mote filter system, follow the OEM or the filter manu-
factures recommendations. Under filling or over filling
the crankcase with oil can cause engine damage.
Illustration 79 g02173847
“L” Low
“H” High
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SEBU9063-03 121
Maintenance Section
Fan Clearance - Check
Illustration 80 g03609316
Typical example
• A is the fan tip clearance 7. Fan tip clearance at position (2) and (3) must be
14 ± 2 mm (0.55 ± 0.079 inch).
1. Set the fan tip clearance at position (1) to 16 mm
(0.63 inch). In Service Information
2. Set the fan tip clearance at position (4) to 12 mm
Ensure that the engine is stopped. Ensure that the
(0.47 inch). cooling system is full.
3. Fan tip clearance at position (2) and (3) must be
14 ± 2 mm (0.55 ± 0.079 inch).
4. Fill the cooling system, for more information refer
to this Operation and Maintenance Manual, “Fluid
Recommendations” for coolant specification.
5. Operate the engine, allow the engine to reach
normal operating temperature. Stop the engine.
Check the coolant level, refer to this Operation
and Maintenance Manual, “Coolant Level - Check”
for more information.
6. Check the fan tip clearance in position (1) and
position (4). The fan tip clearance should be
14 ± 2 mm (0.55 ± 0.079 inch).
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122 SEBU9063-03
Maintenance Section
Fuel Filter (In-Line) - Replace
Illustration 81 g03609316
• A is the fan tip clearance Note: Refer to Systems Operation, Testing, and
Adjusting, “Cleanliness of Fuel System
1. Set the fan tip clearance at position (1) to Components” for detailed information on the
14 ± 2 mm (0.55 ± 0.079 inch). standards of cleanliness that must be observed
during ALL work on the fuel system.
2. Set the fan tip clearance at position (4) to
14 ± 2 mm (0.55 ± 0.079 inch).
NOTICE
3. Fan tip clearance at position (2) and (3) must be Ensure that the engine is stopped before any servic-
14 ± 2 mm (0.55 ± 0.079 inch). ing or repair is performed.
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SEBU9063-03 123
Maintenance Section
Fuel System - Prime
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
1. Turn the fuel supply valve (if equipped) to the OFF 1. Ensure that the fuel system is in working order.
position. Remove any brackets that hold the in-line Check that the fuel supply valve (if equipped) is in
fuel filter (1) in place, refer to OEM information. the “ON” position.
2. Release the hose clips (3) and remove the hose 2. Turn the keyswitch to the “RUN” position.
lines from the in-line fuel filter. Remove the in-line 3. The keyswitch will allow the electric priming pump
filter. to operate. Operate the electric priming pump. The
3. Install a new in-line filter and secure, refer to OEM ECM will stop the pump after 2 minutes.
information. Ensure that the arrow mark (2) is 4. Turn the keyswitch to the “OFF” position. The fuel
aligned to the direction of fuel flow from the tank to system should now be primed and the engine
the fuel pump. should be able to start.
4. Install the fuel hose lines and install the hose clips 5. Operate the engine starter and crank the engine.
(3). Turn the fuel supply valve (if equipped) to the After the engine has started, operate the engine at
ON position. low idle for a minimum of 5 minutes. Ensure that
5. The in-line fuel filter must be changed with the the fuel system is free from leaks.
primary filter and the secondary fuel filter. The fuel
Note: Operating the engine for this period will help
system will need to be primed, refer to Operation ensure that the fuel system is free of air. DO NOT
and Maintenance Manual, “Fuel System - Prime” loosen the high-pressure fuel lines in order to
for more information. purge air from the fuel system. This procedure is
not required.
i05774864
After the engine has stopped, you must wait for 10
Fuel System - Prime minutes in order to allow the fuel pressure to be
purged from the high-pressure fuel lines before any
service or repair is performed on the engine fuel
lines. The 10 minute wait will also allow static charge
Note: Refer to Systems Operation, Testing, and to dissipate from the low-pressure fuel system. If
Adjusting, “Cleanliness of Fuel System necessary, perform minor adjustments. Repair any
Components” for detailed information on the leaks from the low-pressure fuel system and from the
standards of cleanliness that must be observed cooling, lubrication, or air systems. Replace any high-
during ALL work on the fuel system. pressure fuel line that has leaked. Refer to
Disassembly and Assembly Manual, “Fuel Injection
Lines - Install”.
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124 SEBU9063-03
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
i06217529
Note: Refer to Systems Operation, Testing, and 3. Install a suitable tube onto drain (3). Open the
Adjusting, “Cleanliness of Fuel System drain valve (2). Rotate the drain valve
Components” for detailed information on the counterclockwise. Two full turns are required.
standards of cleanliness that must be observed
during ALL work on the fuel system. 4. Loosen the vent screw (1).
5. Allow the fuel to drain into the container. If the fuel
NOTICE will not drain, loosen the vent screw on the
Ensure that the engine is stopped before any servic- secondary fuel filter.
ing or repair is performed.
Note: In some applications, the vent screw on the
secondary fuel filter will need to be open in order to
Remove the Element drain the primary fuel filter.
1. Turn the fuel supply valve (if equipped) to the OFF 6. Remove the tube from the drain valve.
position before performing this maintenance. 7. Tighten the vent screw (1) to a torque of 2.5 N·m
2. Place a suitable container under the water (22 lb in). If necessary, tighten the vent screw on
separator in order to catch any fuel that might spill. the secondary fuel filter. Tighten to a torque of
Clean up any spilled fuel. Clean the outside body 2.5 N·m (22 lb in). Remove the wiring harness
of the filter assembly. from connection (4).
8. Rotate filter bowl (6) counterclockwise and remove
the filter bowl from assembly.
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SEBU9063-03 125
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
Illustration 84 g03858640
Typical example
Illustration 85 g03086798
Typical example
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126 SEBU9063-03
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
i06891342
Illustration 86 g03858194
NOTICE Typical example
Ensure that the engine is stopped before any servic-
ing or repair is performed. 3. Install a suitable tube onto drain (3). Open the
drain valve (2). Rotate the drain valve
counterclockwise. Two full turns are required.
NOTICE
The water separator can be under suction during nor- Loosen vent screw (1).
mal engine operation. Ensure that the drain valve is 4. Visually check that the fluid will drain. Allow the
tightened securely to help prevent air from entering
the fuel system. fluid to drain into the container.
5. When fluid free from water comes from the primary
fuel filter, tighten the drain valve clockwise by hand
Drain Procedure pressure only. Remove the tube and remove the
container.
1. Place a suitable container under the water
separator to catch any fluid that might spill. Clean 6. Tighten the vent screw to a torque of 2.5 N·m
up any spilled fluid. (22 lb in).
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
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SEBU9063-03 127
Maintenance Section
Fuel System Secondary Filter - Replace
Illustration 88 g02546456
Illustration 87 g03088718
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128 SEBU9063-03
Maintenance Section
Fuel Tank Water and Sediment - Drain
3. Do not use a tool in order to install the filter Open the drain valve on the bottom of the fuel tank in
assembly. Tighten the assembly by hand. Install order to drain the water and the sediment. Close the
the filter bowl (2). Turn the filter bowl clockwise drain valve.
until the filter bowl locks into position against the Check the fuel daily. Allow five minutes after the fuel
stops. tank has been filled before draining water and
sediment from the fuel tank.
4. Turn the fuel supply valve to the ON position.
Fill the fuel tank after operating the engine in order to
5. The primary fuel filter the secondary fuel filter must drive out moist air. This will help prevent
be replaced at the same time. Refer to the condensation. Do not fill the tank to the top. The fuel
Operation and Maintenance Manual , “Fuel expands as the fuel gets warm. The tank may
System Primary Filter (Water Separator) Element - overflow.
Replace”. Also, the in-line fuel must be replaced Some fuel tanks use supply pipes that allow water
when the primary and secondary filters are and sediment to settle below the end of the fuel
replaced. Refer to Operation and Maintenance supply pipe. Some fuel tanks use supply lines that
Manual , “Fuel Filter (In-Line)- Replace” take fuel directly from the bottom of the tank. If the
engine is equipped with this system, regular
6. Prime the fuel system. Refer to the Operation and maintenance of the fuel system filter is important.
Maintenance Manual, “Fuel System - Prime” for
more information. Fuel Storage Tanks
i02348492 Drain the water and the sediment from the fuel
storage tank at the following intervals:
Fuel Tank Water and Sediment • Weekly
- Drain • Service intervals
• Refill of the tank
NOTICE This will help prevent water or sediment from being
Care must be taken to ensure that fluids are con- pumped from the storage tank into the engine fuel
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. tank.
Be prepared to collect the fluid with suitable contain- If a bulk storage tank has been refilled or moved
ers before opening any compartment or disassem- recently, allow adequate time for the sediment to
bling any component containing fluids. settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
Dispose of all fluids according to local regulations sediment. Filtering fuel that is pumped from the
and mandates. storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
Fuel quality is critical to the performance and to the Hoses and Clamps - Inspect/
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. 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 Contact with high pressure fuel may cause fluid
fuel tank. This causes water to accumulate in fuel penetration and burn hazards. High pressure fuel
tanks. Draining the fuel tank regularly and obtaining spray may cause a fire hazard. Failure to follow
fuel from reliable sources can help to eliminate water these inspection, maintenance and service in-
in the fuel. structions may cause personal injury or death.
If you inspect the engine in operation, always use the
Drain the Water and the Sediment proper inspection procedure in order to avoid a fluid
Fuel tanks should contain some provision for draining penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
water and draining sediment from the bottom of the
fuel tanks.
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SEBU9063-03 129
Maintenance Section
Radiator - Clean
• Outer covering that is ballooning locally 3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
• Flexible part of the hose that is kinked or crushed
4. Remove the hose clamps.
• Armoring that is embedded in the outer covering
5. Disconnect the old hose.
A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant 6. Replace the old hose with a new hose.
torque hose clamp is the same size as the standard 7. Install the hose clamps with a torque wrench.
clamp.
Note: For the correct coolant, see this Operation and
Due to extreme temperature changes, the hose will
harden. Hardening of the hoses will cause hose Maintenance Manual, “Fluid Recommendations”.
clamps to loosen. This can result in leaks. A constant
torque hose clamp will help to prevent loose hose 8. Refill the cooling system. Refer to the OEM
clamps. information for further information on refilling the
cooling system.
Each installation application can be different. The
differences depend on the following factors: 9. Clean the cooling system filler cap. Inspect the
cooling system filler cap's seals. Replace the
• Type of hose cooling system filler cap if the seals are damaged.
Install the cooling system filler cap.
• Type of fitting material
10. Start the engine. Inspect the cooling system for
• Anticipated expansion and contraction of the hose leaks.
• Anticipated expansion and contraction of the
i05799936
fittings
Radiator - Clean
Replace the Hoses and the Clamps
Refer to the OEM information for further information
on removing and replacing fuel hoses (if equipped).
The following text describes a typical method of
replacing coolant hoses. Refer to the OEM Personal injury can result from air pressure.
information for further information on the coolant
system and the hoses for the coolant system. Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
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130 SEBU9063-03
Maintenance Section
Starting Motor - Inspect
Note: Some applications will require a fuel cooler to After cleaning, start the engine and accelerate the
be installed. The fuel cooler is a type of radiator that engine to high idle rpm. This procedure will help in
uses air to cool the fuel and the fuel cooler will the removal of debris and drying of the core. Stop the
require cleaning. engine. Use a light bulb behind the core in order to
inspect the core for cleanliness. Repeat the cleaning,
Note: Adjust the frequency of cleaning according to if necessary.
the effects of the operating environment.
Inspect the fins for damage. Bent fins may be opened
Inspect the radiator for these items: damaged fins, with a “comb”. Inspect these items for good condition:
corrosion, dirt, grease, insects, leaves, oil and other welds, mounting brackets, air lines, connections,
debris. Clean the radiator, if necessary. clamps and seals. Make repairs, if necessary.
i05805424
Turbocharger - Inspect
NOTICE
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air intake and exhaust sys-
tems. Loss of engine lubricant can result in serious
engine damage.
Minor leakage of oil into a turbocharger under ex-
tended low idle operation should not cause problems
Illustration 90 g03674903 as long as a turbocharger bearing failure has not
Typical example occured.
If the baffle plate (1) has been removed, the baffle When a turbocharger bearing failure is accompanied
plate must be installed again after cleaning. An by a significant engine performance loss (exhaust
engine operating without the baffle plate installed smoke or engine rpm up at no load), do not continue
would not be compliant with emission regulations. engine operation until the turbocharger is renewed.
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SEBU9063-03 131
Maintenance Section
Turbocharger - Inspect
A visual inspection of the turbocharger or 5. Install the air intake pipe and the exhaust outlet
turbochargers can minimize unscheduled downtime. pipe to the turbocharger housing. Ensure that all
A visual inspection of the turbocharger or clamps are installed correctly and that all clamps
turbochargers can also reduce the chance for are tightened securely. For more information, refer
potential damage to other engine parts. Do not
inspect the engine with the engine in operation. to Systems Operation, Testing, and Adjusting,
“Turbocharger - Inspect”.
Single Turbocharger
Engine Install with High Pressure
and Low Pressure Turbochargers
Illustration 91 g02136079
Typical example
Illustration 92 g03676654
1. Ensure that the turbocharger is clean and free from Typical example
dirt before removing components for inspection. (1) High-pressure turbocharger
(2) Elbow
2. Remove the pipe from the turbocharger exhaust (3) Low-pressure turbocharger
outlet and remove the air intake pipe (1). Visually
inspect the piping for the presence of oil. Clean the The engine is equipped with a high-pressure
interior of the pipes in order to prevent dirt from turbocharger (1) and a low-pressure turbocharger
entering during reassembly. (3). A regular visual inspection of both turbochargers
is recommended. If the turbocharger fails during
3. Check for obvious heat discoloration of the engine operation, damage to the turbocharger
turbocharger. Check for any loose bolts or any compressor wheel and/or to the engine may occur.
Damage to the turbocharger compressor wheel can
missing bolts. Check for damage to the oil supply damage the pistons, the valves, and the cylinder
line and the oil drain line. Check for cracks in the head.
housing of the turbocharger. Ensure that the
compressor wheel can rotate freely. Inspecting
4. Check for the presence of oil. If oil is leaking from
the back side of the compressor wheel, there is a NOTICE
possibility of a failed turbocharger oil seal. The compressor housing for the turbocharger must
not be removed from the turbocharger for inspection
The presence of oil may be the result of extended or removed for the cleaning of the compressor.
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 1. Ensure that the turbochargers are clean and free
turbocharger to slobber. from dirt before removing components for
inspection.
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132 SEBU9063-03
Maintenance Section
Walk-Around Inspection
2. Remove the pipe from the high-pressure 7. Install the air intake pipe and the exhaust outlet
turbocharger exhaust outlet and remove the air pipe to the turbocharger housing. Ensure that all
intake pipe to the turbocharger. Visually inspect clamps are installed correctly and that all clamps
the piping for the presence of oil. Clean the interior are tightened securely. For more information, refer
of the pipes in order to prevent dirt from entering to Systems Operation, Testing, and Adjusting,
during reassembly. “Turbocharger - Inspect”.
3. Remove elbow (2) and check for the presence of
i05774869
engine oil.
4. Check for obvious heat discoloration of the Walk-Around Inspection
turbocharger. Check for any loose bolts or any
missing bolts. Check for damage to the oil supply
line and the oil drain line. Check for cracks in the
housing of the turbocharger. Ensure that the
Inspect the Tube of the Crankcase
compressor wheel can rotate freely. Breather
5. 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.
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.
6. Inspect the bore of the housing of the turbine outlet
for corrosion.
Illustration 93 g02137093
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SEBU9063-03 133
Maintenance Section
Walk-Around Inspection
• Wipe all caps and plugs before the engine is Belts for multiple groove pulleys must be replaced as
serviced in order to reduce the chance of system matched sets. If only one belt is replaced, the belt will
contamination. 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.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and High Pressure Fuel Lines
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.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
NOTICE
Accumulated grease and/or oil on an engine is a fire these inspection, maintenance and service in-
hazard. Remove the accumulated grease and oil. Re- structions may cause personal injury or death.
fer to this Operation and Maintenance Manual, “En-
gine - Clean” for more information. After the engine has stopped, wait 10 minutes in
order to allow the fuel pressure to be purged from the
high-pressure fuel lines before any service or repair
• Ensure that the cooling system hoses are correctly is performed. The 10 minute wait will also allow static
charge to dissipate from the low-pressure fuel
clamped and that the cooling system hoses are
system. If necessary, perform minor adjustments.
tight. Check for leaks. Check the condition of all Repair any leaks from the low-pressure fuel system
pipes. and from the cooling, lubrication, or air systems.
Replace any high-pressure fuel line that has leaked.
• Inspect the water pump for coolant leaks. Refer to Disassembly and Assembly Manual, “Fuel
Injection Lines - Install”.
Note: The water pump seal is lubricated by the
coolant in the cooling system. A small amount of If you inspect the engine in operation, always use the
leakage to occur is normal, as the engine cools down proper inspection procedure in order to avoid a fluid
and the parts contract. penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
Excessive coolant leakage may indicate the need to
replace the water pump. Remove the water pump. Visually inspect the high-pressure fuel lines for
Refer to Disassembly and Assembly , “Water Pump - damage or signs of fuel leakage. Replace any
Remove and Install”. damaged high-pressure fuel lines or high-pressure
fuel lines that have leaked.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil Ensure that all clips on the high-pressure fuel lines
pan, the oil filters, and the rocker cover. are in place and that the clips are not loose.
• Inspect the piping for the air intake system and the • Inspect the rest of the fuel system for leaks. Look
elbows for cracks and for loose clamps. Ensure for loose fuel line clamps.
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses. • Drain the water and the sediment from the fuel
tank on a daily basis.
• Ensure that the areas around the rotating parts are
clear. • Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
• Inspect the alternator belts and any accessory wires. Check for any loose tie-wraps or missing
drive belts for cracks, breaks, or other damage. tie-wraps.
• Inspect the wiring harness for damage. • 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
cannot be calibrated.
This document has been printed from SPI2. NOT FOR RESALE
134 SEBU9063-03
Maintenance Section
Water Pump - Inspect
• A piston seizure
• Other potential damage to the engine
Illustration 94 g01904773
(A) Weep hole
(B) Vent hole
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SEBU9063-03 135
Warranty Section
Warranty Information
Emissions Warranty
Information
This document has been printed from SPI2. NOT FOR RESALE
136 SEBU9063-03
Reference Information Section
Reference Materials
Reference Materials
i05204672
Maintenance Records
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SEBU9063-03 137
Reference Information Section
Maintenance Log
i05204675
Maintenance Log
Table 28
Service Quantity Of
Service Item Date Authorization
Hours Fuel
This document has been printed from SPI2. NOT FOR RESALE
138 SEBU9063-03
Reference Information Section
Reference Material
i05204677
Reference Material
(Extended Service Contract)
www.perkins.com
NOTICE
Dependant upon engine type and application.
This document has been printed from SPI2. NOT FOR RESALE
SEBU9063-03 139
Index Section
Index
A Fill .............................................................. 106
Flush .......................................................... 106
After Starting Engine ....................................... 68
Coolant Extender (ELC) - Add ...................... 106
After Stopping Engine ..................................... 76
Coolant Level - Check ................................... 106
Aftercooler Core - Clean/Test (Air-To-Air
Crushing Prevention and Cutting Prevention.. 15
Aftercooler) .................................................. 100
Aftercooler Core - Inspect ............................. 100
Alarms and Shutoffs ........................................ 39 D
Alarms.......................................................... 39 DEF Filler Screen - Clean ............................. 107
Shutoffs........................................................ 39 DEF Manifold Filters - Replace ..................... 108
Testing ......................................................... 40 Diagnostic Flash Code Retrieval..................... 60
Alternator - Inspect ........................................ 100 Diagnostic Lamp.............................................. 60
Alternator and Fan Belts - Replace ............... 100 Diesel Exhaust Fluid - Fill.............................. 108
Diesel Exhaust Fluid Filter - Clean/
B Replace ....................................................... 109
Diesel Exhaust Fluid in Cold Weather............. 75
Battery - Replace........................................... 100
Diesel Exhaust Fluid Tank - Flush..................110
Battery Disconnect Switch .............................. 46
Driven Equipment - Check .............................110
Battery Electrolyte Level - Check .................. 101
Battery or Battery Cable - Disconnect........... 101
Before Starting Engine .............................. 17, 66 E
Belt - Inspect.................................................. 102 Electrical System............................................. 18
Belt Tensioner - Check .................................. 102 Grounding Practices .................................... 18
Burn Prevention................................................11 Emergency Stopping....................................... 76
Aftertreatment System................................. 12 Emissions Certification Film ............................ 31
Batteries....................................................... 12 Emissions Warranty Information ................... 135
Coolant ........................................................ 12 Engaging the Driven Equipment ..................... 69
Diesel Fuel ................................................... 12 Engine - Clean................................................ 111
Induction System ......................................... 12 Aftertreatment ............................................. 111
Oils............................................................... 12 Engine Air Cleaner Element (Dual Element)
- Inspect/Clean/Replace ............................... 111
C Cleaning the Primary Air Cleaner
Elements ...................................................112
Clean Emissions Module Support - Inspect .. 103
Servicing the Air Cleaner Elements............ 111
Cold Weather Operation ................................. 71
Engine Air Cleaner Element (Single
Hints for Cold Weather Operation ............... 71
Element) - Inspect/Replace ..........................113
Idling the Engine .......................................... 72
Engine Air Cleaner Service Indicator -
Recommendations for Coolant Warm Up.... 72
Inspect ..........................................................114
Recommendations for the Coolant.............. 72
Test the Service Indicator ...........................114
Viscosity of the Engine Lubrication Oil ........ 72
Engine Air Precleaner - Check/Clean ............115
Cold Weather Starting ..................................... 66
Engine Crankcase Breather Element -
Configuration Parameters ............................... 61
Replace ........................................................115
Customer Specified Parameters ................. 62
Check the System.......................................116
System Configuration Parameters .............. 61
Engine Diagnostics ......................................... 60
Coolant (DEAC) - Change............................. 103
Engine Electronics........................................... 19
Drain .......................................................... 104
Engine Mounts - Inspect.................................116
Fill .............................................................. 104
Engine Oil and Filter - Change .......................118
Flush .......................................................... 104
Drain the Engine Lubricating Oil.................118
Coolant (ELC) - Change................................ 105
Fill the Oil Pan............................................ 120
Drain .......................................................... 105
This document has been printed from SPI2. NOT FOR RESALE
140 SEBU9063-03
Index Section
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SEBU9063-03 141
Index Section
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142 SEBU9063-03
Index Section
T
Table of Contents .............................................. 3
Turbocharger - Inspect .................................. 130
Engine Install with High Pressure and Low
Pressure Turbochargers .......................... 131
Inspecting .................................................. 131
Single Turbocharger .................................. 131
W
Walk-Around Inspection ................................ 132
High Pressure Fuel Lines .......................... 133
Inspect the Engine for Leaks and for Loose
Connections ............................................. 132
Inspect the Tube of the Crankcase
Breather ................................................... 132
Warranty Information..................................... 135
Warranty Section ........................................... 135
Water Pump - Inspect.................................... 134
Welding on Engines with Electronic
Controls ......................................................... 95
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Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
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SEBU9063
©2017 Perkins Engines Compony Limited All Rights Reserved
144
This document has been printed from SPI2. NOT FOR RESALE