Machine Translated by Google

SEBU7833-03
September 2008

operation and
Maintenance
Manual
1103 and 1104 Industrial Engines
DC (Motor)
DD (Motor)
DJ (Motor)
DK (Motor)
RE (Motor)
RG (Motor)
RJ (Motor)
RR (Motor)
RS (Motor)
TR (Motor)
DF (Motor)
DG (Motor)
Machine Translated by Google

Important Information About Safety

Most accidents involving the operation, maintenance, and repair of the product are caused by non-compliance.
of basic safety rules or precautions. Often, an accident can be avoided by recognizing situations.
potentially dangerous before an accident occurs. A person should be alert to potential dangers. This
The person must also have the training, skills, and tools necessary to perform these functions adequately.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and result in
injuries or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and
understood the information on operation, lubrication, maintenance, and repair.

Safety precautions and warnings are provided in this manual and on the product. If these danger warnings are not
injuries or death may occur to you or to others.

Hazards are identified by the 'Safety Alert Symbol' and followed by a 'Signal Word' such as
"DANGER", "WARNING" or "CAUTION". The "WARNING" label of the safety alert is shown below.

The meaning of this security alert symbol is as follows:

Attention! Stay Alert! Your safety is at stake.

The message that appears under the warning explains the danger and can be presented in writing or illustrated.

The operations that can cause damage to the product are identified by the "WARNING" labels on the product and in this publication.

Perkins cannot foresee all possible circumstances that may involve a potential risk. The warnings
in this publication and in the product are therefore not complete. If a tool, procedure, method is used
work or operational technique that is not specifically recommended by Perkins, you must ensure
that it is safe for you and for others. You should also ensure that the product is not damaged or
unsafe tornado due to the operation, lubrication, maintenance, or repair procedures you choose.

The information, specifications, and illustrations in this publication are based on the information available at the time when the
the publication was written. Specifications, torques, pressures, measurements, adjustments, illustrations, and other items may change
any moment. These changes may affect the service provided to the product. Obtain the complete information and more
current before starting any work. The Perkins dealers or distributors have the most up-to-date information.
available.

When spare parts are needed for this

product, Perkins recommends the use of parts from
Perkins replacement.
Failure to comply with this notice may lead to failures.
premature, damage to the product, personal injuries or
death.
Machine Translated by Google
SEBU7833-03 3
Index

Index

Preface ................................................. ................ 4

Security Section

Security messages ....................................... .... 5

General hazard information .............................. 6

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

Fire Prevention and Explosion Prevention .......... 8

Crush prevention and cutting prevention ........ 10

Assembly and Disassembly ...................... 10

Before Starting the Engine ...................................... 10

Engine start ....................................... ...... 11

Engine stop ....................................... .... 11

Electrical system ................................................ ... 11

Product information section

Views of the model ................................................. ......... 13

Product Identification Information ...................... 19

Operation section

Elevation and storage .............................. 24

Meters and Indicators ...................................... 27

Engine start ................................. 28

Functioning of the engine ................................. 31

Engine stop ....................................... ... 32

Operation in cold weather ...................................... 33

Maintenance Section

Charging capacities .................................................. 37

Maintenance Interval Schedule ....................... 51

Warranty Section

Warranty Information ....................................... 79

Index section

Index .................................................. ................... 80

Machine Translated by Google
4 SEBU7833-03
Preface

Preface The recommended service should be performed at intervals

appropriate, as indicated in the Intervals Table of
Maintenance. The actual operating environment of the engine also
Bibliographic information
regulates the Maintenance Interval Schedule. Therefore,
under extremely severe operating conditions,
This manual contains safety information, instructions
dusty, humid, or very cold, may be necessary
of operation, lubrication and maintenance. This manual
more frequent lubrication and maintenance than the
it must be stored near or within the engine area
specified in the Maintenance Interval Table.
in a literature support or storage area of
literature. Read, study, and keep it along with the literature and
engine information.
The items on the maintenance schedule are organized.
for a maintenance management program
English is the main language of all publications
preventive. If the preventive maintenance program is
from Perkins. The English used facilitates translation and consistency.
periodic adjustment is not necessary.
implementation of a management program
preventive maintenance should minimize costs
Some photographs or illustrations in this manual show
operational through cost reduction resulting from
details or accessories that may be different from yours reduction of unplanned downtime and failures.
motor. Guards and covers may have been removed
for illustrative purposes. Continuous improvement and the advancement of
product design may have caused changes in its Maintenance intervals
motors that are not included in this manual. Whenever
a doubt arises regarding your engine or this one Perform maintenance on items in multiples of the requirement
manual, consult the Perkins dealer or distributor We recommend that the maintenance plans
Perkins to obtain the most available information be reproduced and displayed near the engine as a
recent. convenient reminder. We also recommend that it be
maintained a maintenance record as part of the record
permanent of the engine.
Security
Your authorized Perkins dealer or distributor
This safety section lists basic safety precautions.
Perkins can help you adjust your schedule.
Furthermore, this section identifies situations of
maintenance to meet your needs
dangerous warnings. Read and understand the basic precautions operational environment.
listed in the safety section before operating or
perform lubrication, maintenance, and repair on this product.
review

The main engine overhaul details are not

Operation covered in the Operation and Maintenance Manual,
except for the interval and the maintenance items in it
The operating techniques described in this manual are
interval. Major repairs should be carried out only by
basics. They assist in the development of skills
authorized personnel from Perkins. Your Perkins dealer or
the necessary techniques to operate the engine properly
your Perkins dealer offers a variety of options
more efficient and economical. The skill and techniques are
related to review programs. If you have a
they develop as the operator gains serious engine failure, there are also several options for
knowledge of the engine and its capabilities.
post-failure reviews available. Consult the Perkins dealer
or the Perkins distributor for information about
The operations section is a reference for the operators.
these options.
Photographs and illustrations guide the operator through the
inspection, startup, operation, and shutdown procedures of the
motor. This section also includes a discussion about California Proposition 65 Notice
electronic diagnostic information.
The exhaust of the diesel engine and some of its
constituents are known in the State of California by
Maintenance
cause cancer, birth defects, and other damage
Reproductive. Battery posts, terminals and accessories
The maintenance section is a guide for taking care of the engine.
related contain lead and lead compounds. Wash hands after
The illustrated step-by-step instructions are grouped by
service hours and/or maintenance breaks in the schedule.
The items on the maintenance schedule are referenced
in the detailed instructions below.
Machine Translated by Google
SEBU7833-03 5
Security Section
Security messages

Security Section

i03299360

Security messages

There may be several specific warning signs in a

motor. The exact location of hazards and the description of
hazards are reviewed in this section. Familiarize yourself with all the
warning signs.

Illustration 1 g01154807
Make sure all warning signs are legible.
Clean the warning signs or replace them if the words do not Typical example
they can be read or if the images are not visible.
When the warning signs are clear, use a cloth, water and The universal warning label (1) can be located
soap. Do not use solvents, gasoline, or other chemical products on the valve mechanism cover or in the intake manifold.
aggressive to clean the warning signs. Refer to illustration 2.
Solvents, gasoline or aggressive chemical products can
release the sticker that holds the warning signs. The Note: The location of this label will depend on the application
loose warning signs may fall from the engine. make a motor.

Replace any damaged warning signs or

absent. If a warning sign is affixed to a
motor part that was replaced, install a new board of
warning on the replacement part. The resellers or
Perkins distributors can provide new warning signs.

Do not work on the engine and do not operate the engine unless the
instructions and warnings from the Operation Manual
Maintenance should be understood.
The correct care is your responsibility. Non-compliance
not following instructions or warnings may result in injury or
death.

Universal Notice

Do not operate or work on this equipment unless you have

I read and understood the instructions and warnings in the Manuals. g01682734
Illustration 2
of Operation and Maintenance. Failure to comply with
Instructions or warnings may result in serious injuries. Typical example

or dead.
Ether

Do not use starting aids like aerosol, such as ether. Such

use may result in explosion and personal injury.
Machine Translated by Google
6 SEBU7833-03
Safety Section
General hazard information

i02328435

General hazard information

Illustration 3 g01682820

The warning label for ether (2) is located on the lid of

intake manifold. Refer to illustration 4.

Illustration 5 g00104545

Attach a warning label 'Do not operate' or a label of

warning similar to the starter switch or controls
before performing maintenance on the equipment or before repairing
the equipment.

Illustration 4 g01682833
Illustration 6 g00702020
Typical example

Use helmet, safety goggles, and other equipment

protection, as needed.

Do not wear loose clothing or jewelry that could get caught in the controls.
or in other parts of the engine.

Make sure that all protections and all covers are in place.
trapped in the engine.

Keep the engine free of foreign materials. Remove debris, oil,

tools and other items from the deck, walkways, and steps.

Never put maintenance fluids in glass containers.

Drain all liquids into an appropriate container.

Comply with all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Machine Translated by Google
SEBU7833-03 7
Security Section
Burn prevention

List all the necessary repairs.

Do not allow unauthorized persons to climb on the equipment.

Make sure the power supply is disconnected before

work on the busbar or on the incandescent bulbs.

Perform maintenance on the engine with the equipment in the position of

maintenance. Check the OEM information for obtaining the

procedure to place the equipment in maintenance mode.

Air and Water Pressure

Illustration 7 g00687600
Compressed air and/or water can cause debris and/or
hot water may be expelled. This can result in personal injury.
Always use a plate or cardboard when checking for leaks.
pressurized fluid leakage can penetrate the tissues of the body. The
fluid penetration can cause serious injuries and possible death. A
The direct application of pressurized air or pressurized water on Leakage at the pin hole can cause serious injuries. If the fluid is
the body can result in personal injuries. Injected into your skin, you must receive treatment immediately. Seek
treatment by a doctor who is familiar with this type of injury.

When pressurized air and/or water is used for cleaning, use

protective clothing, safety shoes, and eye protection. A
Eye protection includes safety glasses or a face shield. Containing fluid spill
Care must be taken to ensure that fluids are contained
during the execution of inspection, maintenance, testing, adjustment, and repair
The maximum air pressure for cleaning purposes must be less than 205
kPa (30 psi). The maximum water pressure for cleaning purposes must from the motor. Take measures to collect the fluid with a container
adequate before any compartment is opened or before
be less than 275 kPa (40 psi).
any component can be disassembled.

Fluid penetration Use only appropriate tools for fluid collection and
appropriate equipment for fluid collection.
The pressure can remain trapped in the hydraulic circuit long after the engine
to have been disconnected. The pressure can cause the hydraulic fluid or items
how tube plugs quickly escape if the pressure is not relieved • Use only appropriate tools to contain fluids and equipment
correctly. suitable for containing fluids.

Do not remove any component or hydraulic part until the pressure

it has been alleviated or personal injuries may occur. No Follow all local regulations for the disposal of liquids.
do not disassemble any hydraulic component or part until the
pressure may have been relieved or personal injuries may occur. Consult
the OEM information for any necessary procedures i02143195
to relieve the hydraulic pressure.
Burn prevention

Do not touch any part of a running engine.

Let the engine cool down before performing any maintenance on the engine.
Relieve all pressure in the air system, in the hydraulic system, in the
lubrication system, in the fuel system or in the system of
cooling before disconnecting any lines, connections or
related items.
Machine Translated by Google
8 SEBU7833-03
Security Section
Fire Prevention and Explosion Prevention

soda All fuels, most lubricants, and some mixtures of

Refrigerants are flammable.

When the engine is at operating temperature, the liquid

the engine cooling is hot. The coolant is also under Flammable fluids that leak or spill on hot surfaces
pressure. The radiator and all the lines to the heaters or to the engine or in electrical components can cause fire. The fire can
contain hot soda. to cause personal injuries and material damages.

Any contact with hot soda or steam can cause

severe burns. Leave the components of the cooling system A sudden fire can occur if the engine oil pan covers
cool down before draining the cooling system. forms removed within fifteen minutes after a shutdown of
emergency.
Check the coolant level after the engine has stopped and the
engine has cooled down. Determine if the motor will be operated in an environment that allows entry.
of combustible gases in the air intake system. These gases
Make sure the filling cap is cool before removing it. they can cause excessive speed in the engine. Injuries may occur
The filler cap must be cool enough to be touched with the personal injury, material damage, or damage to the engine.

bare hand. Slowly remove the filling cap to relieve the

pressure.
If the application involves the presence of combustible gases, consult the
The cooling system conditioner contains alkalis. The alkali can Perkins reseller and/or Perkins distributor to obtain information
cause personal injuries. Do not allow the alkali to come into contact additional information about the appropriate protective devices.

with the skin, the eyes, or the mouth.

Remove all combustible or flammable materials.

oils
conductors, such as fuel, oil, and engine debris. Do not allow for
No flammable combustible material or conductive material should accumulate.
Hot oil and hot lubricating components can cause
no motor.
injuries. Do not allow hot oil to come into contact with the skin.
In addition, do not allow hot components to come into contact.
with the skin.
Store fuels and lubricants in containers correctly
marked away from unauthorized persons. Store oily rags and
batteries any flammable materials in protective containers. Do not smoke in
areas used to store flammable materials.
The electrolyte is an acid. The electrolyte can cause personal injury. No
do not allow the electrolyte to come into contact with the skin or eyes. Always
use safety glasses when performing maintenance on batteries. Wash your hands Do not expose the engine to any flames.
after touching the batteries and the connectors. It is recommended to use gloves.

The exhaust protections (if equipped) protect the components

exhaust pipes against oil or fuel splashes in case
failure of a line, pipe, or seal. The exhaust protections must
i02813488
to be installed correctly.

Fire and Explosion Prevention Do not solder on lines or tanks containing flammable fluids. Do not
Prevention cut lines or tanks with flame that contain flammable fluid.
Clean all these lines or tanks completely with a
non-flammable solvent before welding or cutting with a torch.

The wiring must be kept in good condition. All electrical wires

they must be routed correctly and connected securely.
Check all electrical wires daily. Repair any wires.
that are loose or worn before operating the engine. Clean
check all the electrical connections and tighten all the electrical connections.

Remove all wiring that is loose or unnecessary.

Do not use wires or cables smaller than the recommended gauge. Do not ignore.
any fuses and/or circuit breakers.

Illustration 8 g00704000
Machine Translated by Google
SEBU7833-03 9
Security Section
Fire Prevention and Explosion Prevention

Arcs or sparks can cause a fire. Safe connections,

recommended wiring and battery cables with proper maintenance
will help to avoid arcs or sparks.

Inspect all lines and hoses for wear.

or deterioration. The hoses must be routed correctly.
The lines and hoses must have proper support and clamps.
Secure. Tighten all connections to the recommended torque.
Leaks can cause fires.

Oil filters and fuel filters must be installed correctly.

The filter housings must be tightened with the correct torque.

Illustration 10 g00704135

The gases from a battery can explode. Keep any flame away.
open or spark away from the top of the battery. Do not smoke in areas of
battery charging.

Never check the battery charge by inserting a metal object into it.
terminal posts. Use a voltmeter or a hydrometer.

Incorrect connections of the auxiliary cable can cause an explosion.

which may result in injuries. Refer to the Operations Section
from this manual for specific instructions.

Illustration 9 g00704059
Do not charge a frozen battery. This can cause an explosion.
Be careful when refueling an engine. Do not smoke while doing so.
refueling an engine. Do not refuel an engine near flames or
sparks. Always turn off the engine before refueling. The batteries must be kept clean. The caps (if equipped)
must be kept in the cells. Use the cables, connections, and caps
from the battery box recommended when the engine is running.

Fire extinguisher
Make sure a fire extinguisher is available. Familiarize yourself with
on how the fire extinguisher works.
Inspect the fire extinguisher and perform maintenance on the extinguisher
regularly. Follow the recommendations on the instruction plate.

Lines, Pipes, and Hoses

Do not bend high-pressure lines. Do not hit high-pressure lines.
Do not install any line that is bent or damaged. Do not fasten
no other item on the high pressure lines.
Machine Translated by Google
10 SEBU7833-03
Safety Section
Crush prevention and cut prevention

Repair any loose or damaged lines. i01372247

Leaks can cause fires. Consult the Perkins dealer.
or the Perkins dealer for repairs or spare parts. Assembly and Disassembly
Check lines, tubes, and hoses carefully. Do not use the
unprotected hands to check for leaks. Use a board
Use cardboard to check for leaks. Tighten all connections. Inspect the steps, handrails, and work area
with the recommended torque. before assembling the engine. Keep these items clean and in good condition
of conservation.
Replace the parts if any of the following conditions are met
present Get on and off the engine only in places with steps and/or supports.
for hands. Do not climb on the engine and do not jump off the engine.

The connections at the ends are damaged or leaking.

The external coverings are worn or cut.

Stand in front of the engine to assemble or disassemble the engine.
Maintain a three-point contact with the steps and handrails. Use
two feet and one hand or use one foot and two hands. Do not use any
The wires are exposed.
control as support for the hands.
The external coverings are swollen.

Do not climb on components that do not support your weight. Use a

The flexible part of the hoses is bent.
appropriate ladder or use a work platform. Secure the
The outer covers have built-in shielding. climbing equipment so that it does not move.

The final fittings are misaligned.

Do not carry tools or supplies when assembling or disassembling the

Make sure that all clamps, guards, and thermal shields motor. Use a hand line to raise and lower tools or
should be installed correctly. During the operation of the engine, this supplies.
will help to avoid vibration, friction with other parts, and excessive heat.

i02813489

Before starting the engine

i02143194

Prevention of crushing and

Cut prevention Before the initial start of a new engine, during maintenance or
repaired, make sure to turn off the engine to interrupt a
over-speed. This can be done by shutting off the air supply and/or
the engine fuel.
Support the component correctly when working on the component
for executed.
The shutdown due to excessive speed must occur automatically.
Unless other maintenance instructions are provided, never for electronically controlled motors. If the automatic shutdown
try to make adjustments while the engine is running. if it does not occur, press the emergency stop button to cut the
fuel and/or air for the engine.

Stay away from all rotating parts and all parts Inspect the engine for potential hazards.
furniture. Keep the protections in place until the maintenance is done.
completed. After the maintenance, reinstall the protections. Before starting the engine, make sure that no one is
above, below, or near the engine. Make sure that the area
be free from personnel.
Keep objects away from the moving fan blades.
fan blades throw or cut objects. If equipped, check if the engine lighting system is
suitable for the conditions. Make sure all the lights
When hitting objects, use protective goggles to avoid injuries to the function properly, if equipped.
eyes.
All guards and protective covers must be installed if the
shards or other debris can fly off objects when the objects are the motor needs to be turned on to perform the service procedures.
hit. Before hitting objects, make sure that no one will be To help prevent an accident caused by rotating parts,
injured by debris thrown. carefully outline the pieces.
Machine Translated by Google
SEBU7833-03 11
Security Section
Engine start

Do not ignore the automatic shutdown circuits. Do not Note: The engine is equipped with an automatic device
disable the automatic shutdown circuits. The circuits from a cold start for normal operating conditions. If the
are provided to help prevent personal injuries. The motor to be operated in very cold conditions, it may be necessary
circuits are also provided to help prevent damage to an extra cold start auxiliary. Normally, the engine
motor. will be equipped with the correct type of starting aid for
your area of operation.
Refer to the Service Manual for repairs and adjustments.

The engines are equipped with an auxiliary starting spark plug.

i02207232
in each individual cylinder that heats the intake air for
improve the match.
Engine Start
i01928905

Engine stop

Do not use aerosol-type starting aids, such as ether. Such

Stop the engine according to the procedure in the Manual.
use may result in explosion and personal injuries.
Operation and Maintenance, 'Motor Shutdown (Section of
Operation)" to prevent the engine from overheating and the
accelerated wear of engine components.
If there is a warning label on the ignition key of the
engine or controls, DO NOT start the engine or move the
controls. Consult the person who placed the label on Use the emergency stop button (if equipped) ONLY
warning before starting the engine. in an emergency situation. Do not use the stop button of
emergency to stop the engine normally. After a
All protections and protective covers must be installed. emergency stop, DO NOT start the engine until the
if the engine needs to be turned on to carry out the procedures the problem that caused the emergency stop has been corrected.
of service. To help prevent an accident caused by parts
while rotating, carefully outline the pieces.
Stop the engine if an excess condition occurs.
speed during the initial run of a new engine or of a
Start the engine in the operator's compartment or with the key engine that has been serviced. This can be done by turning off the supply
engine start. fuel for the engine and/or turning off the supply of
to the engine.
Always start the engine according to the procedure.
described in the Operation and Maintenance Manual, topic 'Start-up
i02176668
"Motor" in the Operation Section. Know the procedure
correct will help avoid greater damage to the components of Electrical system
motor.
Knowing the procedure will also help to avoid injuries
personal.
Never disconnect any circuit from the charging unit
To ensure that the water heater of the jacket (if equipped) and/
you connect the battery circuit terminal when the unit of
or the lubricating oil heater (if equipped) be
loading is in operation. A spark can cause
working correctly, check the temperature gauge of the
the ignition of combustible gases produced by some batteries.
water and the oil temperature gauge during the heater operation.

To help prevent sparks from flammable gases

The engine exhaust contains combustion products
produced by some batteries, the auxiliary starting cable
that can be harmful to health. Always start the engine and operate- “-”
negative must be connected last from the power supply
or in a well-ventilated area. If the engine is turned on in a
external to the negative terminal "-" of the starter motor. If the motor
closed area, vent the engine exhaust outside.
if the departure is not equipped with a negative terminal, connect
“-”
the auxiliary jumper cable to the engine block.
Machine Translated by Google
12 SEBU7833-03
Security Section
Electric system

Check the electrical wires daily for any wires

loose or worn. Tighten all the loose electrical wires
Before starting the engine. Check all the electrical wires
worn before starting the engine. Please refer to the Manual of
Operation and Maintenance for specific instructions of
game.

Grounding practices
The correct grounding of the motor's electrical system is
necessary for great performance and reliability
do motor. Incorrect grounding will result in paths
of uncontrolled electrical circuit and in circuit paths
unreliable electrical

Uncontrolled electrical circuits can result in

damage to the main bearings, to the surfaces of the bearings
of the crankshaft and the aluminum components.

Motors installed without grounding straps.

structures can be damaged by electric discharge.

To ensure that the engine and the engine's electrical systems

to function correctly, a belt must be used
motor-structure grounding with a direct path to the
battery. This path can be provided through a
direct grounding of the motor to the structure.

All groundings must be firm and free of corrosion.

The engine alternator must be grounded to the negative terminal.
- of the battery with a suitable wire to support all the
alternator load current.
Machine Translated by Google
SEBU7833-03 13
Product information section
Model Views

product information
Section

Model views

i01928892

Model view illustrations

1104 Views of the Engine Model

Illustration 11 g01012280

Valve mechanism cap Fuel injection pump Water pump

Crankcase breather Engine oil filter Fan pulley
(3) Fuel filter Crankshaft pulley Water temperature regulator housing
Machine Translated by Google
14 SEBU7833-03
Product information section
Model views

Illustration 12 g01012281

Oil filler cap Turbocompressor Steering Wheel

Exhaust collector Starter motor Air inlet
Alternator Flywheel casing
Machine Translated by Google
SEBU7833-03 15
Product information section
Model views

1103 Views of the Engine Model

Illustration 13
g01011348

Alternator Supply of turbocharger oil (5) Turbocompressor (6)

(2) Fan pulley Turbocharger oil drain exhaust collector
Machine Translated by Google
16 SEBU7833-03
Product information section
Model views

Illustration 14 g01011349

Fuel transfer pump Rod Water pump

Oil filler cap Oil filter Water temperature regulator casing
Fuel filter Oil pan
Starter motor Crankshaft pulley

i02196981 Naturally aspirated

Engine description
Engine specifications
Note: The front end of the engine is opposite to the
Perkins engines are designed for the following end of the engine crankshaft. The left and
applications: machines, generator sets and equipment the rights of the driver are determined from the end of the
industrial furniture. The engines are available in steering wheel. Cylinder number 1 is the front cylinder.
the following types of aspiration:

Post-cooled turbocharged

Turbocharged
Machine Translated by Google
SEBU7833-03 17
Product information section
Model views

table 2

1103 Industrial Engine Specifications

Number of cylinders 3 in a row

Caliber 105 millimeters (4.134 inches)

AVC 127 millimeters (5.0 inches)

Aspiration Turbocharged
naturally aspirated

Compression rate NA 19.25:1 T

18.25:1

Displacement 3.3 L (201 in³)

Firing Order 123

Illustration 15 g00984281
Rotation (steering wheel end) Counterclockwise
A typical example of the valve layout
A) Inlet valves
Adjustment of the valve clearance (intake) 0.20 mm (0.008 in)
B) Escape valves
Valve clearance adjustment 0.45 mm (0.018 in)
(Escape)
table 1

1104 Industrial Engine Specifications Table 3

Number of cylinders 4 in a row

1104 Specifications of the generator set
Caliber 105 millimeters (4.134 inches)
Number of cylinders 4 in a row

AVC 127 millimeters (5.0 inches) Caliber 105 millimeters (4.134 inches)

Aspiration Turbocharged aftercooler AVC 127 millimeters (5.0 inches)

Turbocharged
naturally aspirated Aspiration Turbocharged aftercooled
Turbocharged
Compression rate NA 19.25:1 NA T
naturally aspirated
18.23:1 T, TA
Compression rates NA 19.25:1 T
3
Displacement 4.4 L (268 pol.) ) 17.25:1

Fire Order 1342

3
Counterclockwise Displacement 4.4 L (268 points) )
Rotation (steering wheel end)

Fire Order 1342

Adjustment of the valve clearance (intake) 0.20 mm (0.008 in)
Rotation (steering wheel end) Counterclockwise
Valve clearance adjustment
0.45 mm (0.018 in.)
(Escape) Adjustment of the valve clearance (intake) 0.20 mm (0.008 in.)

Valve clearance adjustment

0.45 mm (0.018 in.)
(Escape)
Machine Translated by Google
18 SEBU7833-03
Product information section
Model views

Table 4 Engine lifespan

1103 Generator group specifications
The efficiency of the engine and the maximum utilization of the engine's performance
Number of cylinders 3 in a row depend on the compliance with the appropriate recommendations of

Caliber operation and maintenance. In addition, use the fuels, liquids of

105 millimeters (4.134 inches)
cooling and recommended lubricants. Refer to the Manual of
AVC 127 millimeters (5.0 inches) Operation and Maintenance as a guide for maintenance
necessary of the engine.
Aspiration Turbocharged
naturally aspirated
The expected lifespan of the engine is generally predicted by the average power.
Compression rate NA 19.25:1 T
required. The average power required is based on the fuel consumption of
17.25:1
motor for a period of time. Reduced operating hours in
Displacement 3.3 L (201 in³) total acceleration and/or operation in reduced acceleration configurations
result in a lower average energy demand. Operating hours
Order of Fire 123
reduced will increase the duration of operating time before
Rotation (end of the steering wheel) Counterclockwise an engine overhaul may be necessary.

Adjustment of the valve clearance (inlet) 0.20 mm (0.008 in)

Valve clearance adjustment 0.45 mm (0.018 in.)

Escape

Cooling and Lubrication of the Engine

The cooling system consists of the following components:

Gear-driven centrifugal water pump

Water temperature regulator that regulates the

coolant temperature of the engine

Gear-driven oil pump (gear type)

Oil cooler

The engine lubricant oil is supplied by a type of pump

gear. The engine lubricant oil is cooled and the lubricant oil
The motor is filtered. The bypass valves provide unrestricted oil flow.
lubricant for engine parts when the oil viscosity is
high. The divert valves can also provide unrestricted flow of oil
lubricant for the engine parts if the oil radiator gets clogged
or if the oil filter element is clogged.

The engine efficiency, the emission control efficiency and the performance
motors depend on following the appropriate recommendations of
operation and maintenance.
The performance and efficiency of the engine also depend on the use of
fuels, lubricating oils and recommended cooling liquids.
Refer to the Operation and Maintenance Manual, 'Schedule of
Maintenance Intervals for more information about the items
of maintenance.
Machine Translated by Google
SEBU7833-03 19
Product information section
Product identification information

Product identification i01940474

Information Serial number plate

i02280116

Engine identification

Perkins engines are identified by a serial number.

This number is displayed on a mounted serial number plate.
on the left side of the engine block.

An example of an engine number is RE12345U090001H.

RE _____________________________________________Type of motor

RE12345__________________________ Engine list number

You ____________________________ Built in the United Kingdom

090001 ___________________________ Engine serial number

H _____________________________________Year of Manufacture g00994966

Illustration 16

Perkins dealers need these numbers to determine Typical serial number plate

the components included in the engine. This allows for identification Temporary Parts List Number
(2) Type
I need the part numbers for the replacement parts.
Serial number
List number

The serial number plate is located on the left side of the block.
cylinders behind the high-pressure injection pump tubes of
fuel.

The following information is printed on the plate of number

series: engine serial number, model and arrangement number.

i02164876

Reference numbers

Information for the following items may be required for

order parts. Locate the information for your engine.
Register the information in the appropriate space.
Make a copy of this list for record-keeping. Keep the information.
for future reference.

Reference Registration

Engine model _______________________________________________

Engine serial number

Low rotation of the engine _______________________________________

Machine Translated by Google
20 SEBU7833-03
Product information section
Product identification information

Total engine load rotation _____________________________________

Primary fuel filter

Water separator element

Secondary fuel filter element

Oil filter element ___________________________

Auxiliary Oil Filtering Element

Total Capacity of the Lubrication System _____________________

Total cooling system capacity _________________________

Air purifier element

Fan drive belt _______________________________________________

Alternator belt

i02758852

Emission Certification Film

Label for compatible motors

Typical examples of emission labels
Machine Translated by Google
SEBU7833-03 21
Product Information Section
Product identification information

Illustration 17 g01173630

This typical label is installed on engines that have electronic fuel injection systems and installed on engines that have electronic injection pumps.
of fuel.

Illustration 18 g01156733

This typical label example is installed on engines that have mechanical fuel injection pumps.
Machine Translated by Google
22 SEBU7833-03
Product information section
Product identification information

Label for motors that comply with

MSHA emissions

Illustration 19 g01381316

Typical example

The label shown in illustration 19 is for engines that operate in

underground coal mines in North America. The label
is installed in engines that meet Mine Safety emissions
and Health Administration (MSHA). Diesel engines
approved ones must be identified by an approved mark
legible and permanent. The approved mark is inscribed with the
MSHA approved number. The label must be securely attached to
diesel engine.

Label for motors that do not

compliance with the emissions

Illustration 20 g01156734

This typical label is installed on engines that do not meet emissions.

Machine Translated by Google
SEBU7833-03 23
Product information section
Product identification information

Illustration 21 g01157127

This typical label example is installed on stationary engines.

Machine Translated by Google
24 SEBU7833-03
Operation section
Elevation and Storage

Operations section Some removals require the lifting of the fixings to

obtain the correct balance and safety.

To remove ONLY the engine, use the lift eyes.

Elevation and Storage that are in the engine.

The elevation skylights are designed and installed for arrangements

i02164186 specifics of the engine. Changes to the lifting eyes and/or in
motors render obsolete the lifting eyes and the devices of
Engine lift elevation. If changes are made, make sure that the
correct lifting devices are provided. Consult
the Perkins dealer or the Perkins distributor to obtain
information about accessories for correct lifting
of motor.

i01930351

Engine Storage

If the engine is not started for several weeks, the lubricating oil
will be drained from the walls of the cylinder and the piston rings. A
rust can form on the walls of the cylinder. The rust
the walls of the cylinder will cause greater wear on the engine and
reduction of the engine's lifespan.

Lubrication system
To help prevent excessive wear of the engine, use the
following guidelines:

Complete all lubrication recommendations listed in this

Operation and Maintenance Manual, "Schedule of Intervals
of Maintenance" (Maintenance Section).

If an engine is out of operation and if the use of the engine is not

planned, special precautions must be taken.
Illustration 22 g01097527
If the engine is stored for more than a month, it is recommended
a complete protection procedure.
NOTICE
Never fold the eyelets and the supports. Carry only the eyelets. Use the following guidelines:
and the supports under tension. Remember that the capacity of a
the eye is smaller when the angle between the support members and the Completely clean the external part of the engine.
the object becomes smaller than 90 degrees.
Completely drain the fuel system and
refuel the system with preservative fuel.
When it is necessary to remove an angled component, use 1772204 POWERPART Lay-Up 1 can be mixed
just a joint support with appropriate classification with normal fuel to transform the fuel
for the weight. in preservative fuel.

If the preservative fuel is not available, the system of

Use a hoist to remove heavy components. Use fuel can be filled with regular fuel. This
an adjustable lifting beam to lift the engine. fuel must be discarded at the end of the storage period
All support members (chains and cables) must be together with the fuel filtering elements.
parallel to each other. The currents and cables must be
perpendicular to the top of the object being lifted. • Operate the engine until it reaches the normal temperature of
operation. Stop any fuel, oil leak
lubricant or air systems. Turn off the engine and drain the oil
sump lubricant.
Machine Translated by Google
SEBU7833-03 25
Operation section
Lifting and storage

• Replace the lubricating oil filter(s) container(s). 4. Open the faucet or remove the drainage plug in
bottom part of the radiator to drain the radiator.
Fill the oil sump to the Full mark on the dipstick with oil. If the radiator does not have a tap or drain plug,
new and clean lubricant. Add 1762811 POWERPART disconnect the hose at the bottom of the radiator.
Lay-Up 2 oil to protect the engine against corrosion.
If 1762811 POWERPART Lay-Up 2 is not available, 5. Wash the cooling system with clean water.
use a preservative of the correct specification instead of oil
lubricant. If a preservative is used, it must be [Link] the drainage plugs and the fill cap. Close the faucet.
completely drained at the end of the period of Connect the radiator hose.
storage and the oil pan must be refilled to the level
correct with normal lubricant oil. [Link] the cooling system with an approved product.
antifreeze mixture, as it provides protection against corrosion. The
the maximum flow rate is 1 L (0.2200 Imp gal) per minute for
fill the system.
Cooling system

To help prevent excessive engine wear, use the

Note: Certain corrosion inhibitors can cause damage to
following guidelines:
some components of the engine. Contact the
Perkins Services Department for guidance.
NOTICE
Do not drain the coolant while the engine is still running. 8. Operate the engine for a short period so that the lubricating oil
hot and the system under pressure, as the coolant and the refrigerant fluid circulates in the engine.
hot and dangerous can be discharged.

[Link] the battery. Place the battery in storage

If freezing temperatures are expected, check
sure in a totally loaded condition. Before
the cooling system for adequate protection against
store the battery, protect the terminals against
freezing. Please refer to this Operation Manual and
corrosion.1734115 POWERPART Lay-Up 3 can be used in
Maintenance, "General Information about Soft Drinks" (Section of
end.
Maintenance).
10. Clean the breather of the crankcase, if one is installed.
NOTICE Select the end of the tube.
To prevent freeze damage, make sure that all the
coolant should be removed from the engine. This is important. [Link] the fuel injectors and spray
if the system is drained after being washed with water or if 1762811 POWERPART Lay-Up 2 for one or two seconds in
a very weak antifreeze solution to protect the system from each hole of the cylinder with the piston at BDC.
ice having been used.

12. Slowly turn the crankshaft for one complete turn and,
next, replace the fuel injectors.

Induction System

Remove the air filter set. If necessary, remove

the tubes that are installed between the filter set of
It is the turbocharger.
Pulverize 1762811 POWERPART Lay-Up 2 no turbocharger.
The duration of the spraying is printed on the container. See the
turbocompressor with waterproof tape.

Illustration 23 g01003928

Exhaust system
1. Make sure the vehicle is on level ground.
Remove the exhaust pipe. Spray 1762811
2. Remove the coolant system filler cap. POWERPART Lay-Up 2 no turbocharger. The duration of the
spraying is printed on the container.
3. Remove the drain plug (1) from the side of See the turbocharger with waterproof tape.
cylinder block to drain the engine. Make sure that the
drainage opening is not obstructed.
Machine Translated by Google
26 SEBU7833-03
Operation section
Elevation and Storage

General items

If the lubricating oil filling is installed in the rocker arm

tampa, remove the fuel cap. If the filling cap of
if lubricating oil is not installed on the rocker cover, remove it
the balance cover. Spray 1762811 POWERPART Lay-Up 2 to
around the set of the rocker axis.
Replace the filler cap or the balancing cap.

• Leads to the ventilation of the fuel tank or the cap of the tank
fuel with waterproof tape.

Remove the drive belts from the alternator and put the drive on.
belts in storage.

To avoid corrosion, spray the engine with 1734115 POWERPART Lay-Up

3. Do not spray the area inside the alternator.

When engine protection is completed according to these instructions,

this ensures that there will be no corrosion. Perkins is not responsible for
damage that may occur when an engine is stored after a
service period.

The Perkins dealer or the Perkins distributor can help prepare the
engine for long storage periods.
Machine Translated by Google
SEBU7833-03 27
Operation section
Meters and Indicators

Meters and Indicators Reduce the load and the engine speed.

Inspect the cooling system for leaks.

i02164190
3. Determine if the engine should be turned off
Meters and Indicators immediately or if the engine can be cooled down
load.

Tachometer - This gauge indicates the speed of the engine.

Your engine may not have the same gauges or all the gauges. (rpm). When the throttle control lever is
described. For more information about the meter package, moved to the maximum acceleration position without load,
consult the OEM information. the engine is running at high RPM. The engine is running at
maximum load rotation when the throttle control lever
The gauges provide indications about the engine performance. It is in the position of maximum acceleration with maximum nominal load.
Make sure the meters are in good working condition.
Determine the normal operating range by observing the meters during
a period of time.
WARNING

Noticeable changes in the meter readings indicate possible To help avoid damage to the engine, never exceed the high RPM.
problems in the meter or in the engine. Problems can also be rotation. Excessive speed can result in serious damage to
indicated by meter readings that change even if the engine. The engine can be operated at high speed without damage, but never

readings are within specifications. must exceed high-speed revolutions.

Determine and correct the cause of any significant change in
readings. Consult the Perkins dealer or Perkins distributor for
get assistance.
Ammeter - This meter indicates the amount
of loading or unloading in the charging circuit of the
NOTICE If battery. operation of
no oil pressure is indicated, STOP the engine. If the temperature the indicator must be on the right side of "0" (zero).
maximum engine coolant temperature has been exceeded, STOP the engine. You may
damages to the engine.
Fuel level – This gauge indicates the level of
fuel in the fuel tank. The gauge of
Engine oil pressure - The oil pressure must fuel level works when the "START/STOP" switch
is maximum after the cold engine has started. The pressure is in the 'ON' position.

the typical motor oil with SAE10W30 is 207 to 413 kPa

(30 to 60 psi) at nominal rpm. Service hour counter – The meter indicates the time
of engine operation.

A lower oil pressure is normal at idle. If the load

if it is stable and the meter reading changes, execute the following
procedure:

Remove the load.

2. Reduce the engine speed to low RPM.

3. Check and maintain the oil level.

Cooling liquid temperature of the jacket

The typical temperature range is from 71 to 96°C (160 to
205°F). The maximum allowed temperature with the system
The pressurized cooling at 48 kPa (7 psi) is 110°C (230°F).
Higher temperatures can occur under certain conditions. The reading
the temperature of the water can vary according to the load. The
reading should never exceed the boiling point of the pressurized system
what is being used.

If the engine is operating above the normal range and the steam is
to make apparent, execute the following procedure:
Machine Translated by Google
28 SEBU7833-03
Operation section
Engine Start

Engine Start Do not start the engine or move any of the controls if there is
a warning label "DO NOT OPERATE" or label of
similar warning attached to the starting key or controls.
i02194223

Before starting the engine Make sure that the areas around the rotating parts are
sure.

All protections must be in place. Check for

Before starting the engine, perform the necessary daily maintenance and damaged or missing protections. Repair any protections
any other periodic maintenance that is necessary. damaged. Replace damaged and/or missing protections.
Refer to the Operation and Maintenance Manual, "Schedule of
Maintenance Intervals for more information.
Disconnect any battery chargers that are not
protected against the high current drain that is created when
To maximize the engine's lifespan, perform a complete inspection inside. The starting electric motor is activated. Check the cables.
of the engine compartment before starting the engine. Look for the following check the battery for poor connections and corrosion.
itens: vazamentos de óleo, vazamentos de refrigerante, parafusos
loose and excess dirt and/or grease. Remove any excess
of dirt and/or grease buildup. Repair the identified damages • Redefine all disconnections or alarm components (if
during the inspection. equipped.

Check the engine oil level. Maintain the oil level.

Inspect the cooling system hoses for cracks and between the "ADD" mark and the "FULL" mark on the oil level gauge
for loose braces. do motor.

Inspect the alternator and accessory belts for Check the level of the coolant. Observe the liquid level.
cracks, breaks and other damages. refrigerant in the main tank (if equipped). Maintain the level
of coolant liquid in the brand 'FULL' in the main tank.
• Inspect the wiring for loose connections and
worn wires or worn wires.
If the engine is not equipped with a collection tank
• Check the fuel supply. Drain the water from the separator. keep the coolant level within 13 mm (0.5 in)
water (if equipped). Open the fuel supply valve at the bottom of the filling tube. If the engine is
(is equipped). equipped with a glass display, keep the liquid level of
cooling on the display.
NOTICE
All valves on the fuel return line must be opened. • Observe the air filter maintenance indicator (if
before and during the operation of the engine to help prevent high pressure equipped). Perform maintenance on the air filter when the diaphragm

fuel. The high pressure of the fuel can cause failure in the casing yellow entering the red zone or when the red piston
of the filter or other damage. lock in the visible position.

• Make sure that any equipment driven by the motor has been
If the engine is not started for several weeks, the fuel may have disconnected from the engine.
has been drained from the fuel system. Air may have entered the Minimize electrical charges or remove any electrical charges.
filter housing. Additionally, when the fuel filters are
exchanged, some air bags will get stuck in the engine. In these cases,
check the fuel system. Refer to the Operation Manual and
Maintenance, 'Fuel System - Scour' to obtain more
information on how to bleed the fuel system.

The engine exhaust contains combustion products that can

are harmful to health. Always turn on and operate the engine in an area
well ventilated and, if in an enclosed area, ventilate it
exhaust to the outside.
Machine Translated by Google
SEBU7833-03 29
Operation Section
Engine Start

i02198348 When Group 2 diesel fuel is used, the following items

they provide a way to minimize startup issues and problems
Starting the Engine fuel in cold weather: engine oil pan heaters,
shirt water heaters, fuel heaters and
fuel line isolation.

Use the following procedure for starting in cold weather.

Do not use starting aids such as aerosol, like ether. Such

use can result in explosion and personal injury. [Link] equipped, move the throttle lever to the position
of the maximum acceleration before starting the engine.

2. When equipped, turn the engine ignition key to the position

Check the OMM for your type of control. Use the following Heating position. Keep the start switch pressed
procedure to start the engine. run the engine in HEAT position for 6 seconds until the light
the incandescent bulb indicator will light up. This will activate the
1. If equipped, move the throttle lever to the position incandescent spark plugs will help in starting the engine.
of maximum acceleration before starting the engine.

NOTICE
NOTICE
Do not start the engine for more than 30 seconds.
Do not start the engine for more than 30 seconds. Let the starting electric motor cool for two minutes before
Let the starting electric motor cool for two minutes before activate the engine again.
turn on the engine again.

3. While the indicator light of the incandescent bulb is on,

2. Turn the engine start key to the START position. turn the engine starter key to the START position and activate it
Hold the engine starter key in the START position and activate the engine.
the engine.
Note: If the indicator light of the glow plug
3. When the engine starts, release the engine starter button light up quickly for 2 to 3 seconds, or if the indicator light of the
exchange. the incandescent bulb does not light up, there is a malfunction in the
cold start system. Do not use ether or other starting fluids
4. If equipped, slowly move the throttle lever to the to start the engine.
low idle position and let the engine idle.
Refer to the topic "After Engine Shutdown" in the Manual of 4. When the engine starts, release the ignition key.
Operation and Maintenance.

5. If the engine doesn't start, release the engine 5. If the engine does not start, release the engine starter key.
starter switch and let the starter electric motor cool down. and let the starter motor cool down.
Then, repeat steps 2 to 4. Next, repeat steps 2 to 4.

Turn the engine starter key to the OFF position to turn it off. 6. If the engine is equipped with a throttle, leave the engine
the engine. at a slow pace for three to five minutes, or leave the engine on
slow march until the water temperature gauge starts
to ascend. The engine must run smoothly at low revs
i02198092
until the speed is gradually increased to high

Cold weather departure rotation. Let the white smoke disperse before
proceed with normal operation.

7. Operate the engine under low load until all systems

they reach the operating temperature. Check the meters
during the heating period.

Do not use starting aids such as aerosol, like ether. Such Turn the engine start key to the OFF position to turn it off.
use can result in explosion and personal injuries. the engine.

The starting capacity will be improved at temperatures below.

from -18 °C (0 °F) using a jacketed water heater
or extra battery capacity.
Machine Translated by Google
30 SEBU7833-03
Operation section
Engine Start

i02177935 3. Connect one negative end of the jump start cable to

negative terminal of the power supply cable. Connect the other one
Starting with Jump Start negative end of the jump start cable to the block of
Cables motor or to the grounding of the chassis. This procedure helps
to prevent possible ignition sparks from combustible gases
produced by some batteries.

4. Turn on the engine.

Incorrect connections of the auxiliary starting cable can cause a 5. Immediately after the engine is stopped,
explosion, resulting in personal injuries. disconnect the auxiliary starting cables in reverse order.

Avoid sparks near batteries. Sparks can cause After the auxiliary start, the alternator may not be able to recharge.
the vapors explode. Do not allow the ends of the cable totally the batteries that are severely discharged.
starting auxiliaries contact each other or with the engine. The batteries should be replaced or charged with the voltage.
correct with a battery charger after the engine is turned off.
Many batteries considered unusable are still rechargeable.
Note: If possible, first diagnose the reason for the failure of
Refer to the Operation and Maintenance Manual, 'Battery - Replace'
departure. Make all necessary repairs. If the engine does not
and the Testing and Adjustment Manual, "Battery - Test."
The game only due to the battery condition, charge it.
battery or start the engine with jumper cables.

The condition of the battery can be checked again later.

i01903609
that the engine is turned off.

After starting the engine

NOTICE
Use a battery source with the same voltage as the electric motor.
startup. Use ONLY equal voltage for auxiliary starting. The use of voltage Note: At temperatures from 0 to 60°C (32 to 140°F), the time of

higher will damage the electrical system. Heating is approximately three minutes. At temperatures
below 0°C (32°F), heating time may be necessary
additional.
Do not reverse the battery cables. The alternator may be damaged.
Connect the ground cable last and remove it first. When the engine is idling during warming up,
observe the following conditions:

When using an external power source to start the engine, turn the Check for any fluid or air leaks at idle.
and a half rotation (without load on the engine) before operating the engine
control key of the generator set to the position 'OFF'. TURN OFF
all electrical accessories before connecting the auxiliary cables of under load. This is not possible in some applications.
departure.

Make sure the main power switch is in the • Operate the engine at low speed until all systems
position OFF before connecting the auxiliary starting cables reach the operating temperatures. Check all the meters
to the motor that is being turned on. during the heating period.

Note: The readings from the meters must be observed and the
1. Turn the ignition key to the OFF position. Turn off. data must be recorded frequently while the engine
all the engine accessories. is working. The comparison of data over time
will help to determine the normal readings for each meter. A
2. Connect one positive end of the jump starter cable to data comparison over time will also help to
positive terminal of the discharged battery cable. Connect it to the detect abnormal operational developments. Changes
the other positive end of the jump lead to the terminal significant readings must be investigated.
positive of the power supply cable.
Machine Translated by Google
SEBU7833-03 31
Operation section
Engine operation

Engine operation i02330149

Fuel Conservation Practices

i02176671

Engine operation
The efficiency of the engine can affect fuel economy.
the design and manufacturing technology of Perkins provide
maximum fuel efficiency in all applications. Follow the
The correct operation and maintenance are fundamental factors to achieve the recommended procedures to achieve optimal performance throughout life
maximum lifespan and engine savings. If the instructions in the Manual engine useful.
if Operations and Maintenance are followed, costs can be
minimized and the lifespan of the engine can be maximized.
Avoid spilling fuel.

The engine can be operated at nominal speed after the engine reaches the The fuel expands when the fuel is heated. The fuel can
operating temperature. The engine will reach the operating temperature overflow from the fuel tank. Inspect the fuel lines for
normal but earlier during a low engine rotation (rpm) and Leaks. Repair the fuel lines as needed.

during a low energy demand. This procedure is more

more effective than leaving the engine idling without load. The engine must Know the properties of different fuels.
reach operating temperature in a few minutes. Only use the recommended fuels.

Avoid unnecessary slow driving.

The readings from the meters must be observed and the data must be
frequently recorded while the engine is running. Turn off the engine instead of idling for long periods of time.
The comparison of data over time will help to determine
the normal readings for each meter.
The comparison of data over time will also help to • Check the air filter maintenance indicator regularly.
detect unusual operational developments. Changes Keep the air purifier elements clean.
Significant findings in the readings should be investigated.
• Perform maintenance on electrical systems.

i01929404 A damaged battery cell will overload the alternator.

This will consume excessive energy and fuel.
Engine warming
Make sure that the drive belts are properly adjusted.
The drive belts must be in good condition.

1. Run the engine at low RPM for three to five minutes, or leave it
Make sure that all hose connections are secure.
engine at low revs until the water jacket temperature
tight. The connections should not leak.
start climbing.

Make sure that the activated equipment is in good condition.

More time may be necessary when the temperature
operating conditions.
is below -18°C (0°F).

Cold engines consume excess fuel. Use the heat of

2. Check all the meters during heating
water system of the shirt and the exhaust system, when
period.
possible. Keep the components of the cooling system
clean and in good condition. Never operate the engine
3. Perform a general inspection. Check the engine for leaks.
without the water temperature regulators.
of fluid and air leaks.

All these items will help maintain operational temperatures.

4. Increase the rotation to the nominal rotation. Check if there is
fluid leaks and air leaks. The engine can be
operated at nominal total rotation and under full load when the
the water shirt temperature reaches 60°C (140°F).
Machine Translated by Google
32 SEBU7833-03
Operation section
Engine stop

Engine stop i01903608

After Stopping the Engine

i01929389

Stopping the engine

Note: Before checking the engine oil, do not operate the engine for
at least 10 minutes to allow the engine oil to return to
cart
ATTENTION
• Check the oil level in the sump. Keep the oil level between the
Stopping the engine immediately after having worked under load can result in
mark "ADD" and the mark "FULL" on the oil level dipstick.
in overheating and accelerated wear of engine components.

If necessary, make small adjustments. Fix any leaks

If the engine is operating at high speeds and/or high loads, operate
and tighten the loose screws.
at low speed for at least three minutes to reduce and stabilize
the internal temperature of the engine before turning off the engine.
• Observe the necessary maintenance interval. Execute
the maintenance listed in the Operating Manual and
Maintenance, 'Maintenance Interval Schedule'.
Avoiding hot engine shutdowns will maximize the lifespan of the shaft
of the turbo compressor and of the bearing.

Fill the fuel tank to help prevent

Before turning off a motor that is being operated under load accumulation of moisture in the fuel. Do not overfill the tank
at low speeds, run the engine at low RPM for 30 seconds before fuel.
stop. If the engine is operating at highway speeds and/
or at high loads, run the engine at idle for at least NOTICE Use
three minutes. This procedure will cause the temperature only recommended antifreeze/coolant mixtures in the
the internal engine component should be reduced and stabilized.
Specifications of the refrigerant fluid that are in the operation manual
and maintenance. Not doing this can cause damage to the engine.

Make sure that the engine shutdown procedure is

understood. Stop the engine according to the shutdown system.
of the engine or refer to the instructions provided by the OEM. Let the engine cool down. Check the coolant level.

If freezing temperatures are expected, check if the

To turn off the engine, turn the ignition key to coolant has the correct antifreeze protection. The
the OFF position. the refrigeration system must be protected against freezing up to
the lowest expected external temperature. Add the mix
correct soda/water, if necessary.
i01903586
• Carry out all necessary periodic maintenance on all
Emergency stop Equipment activated. This maintenance is described in the instructions.
do OEM.

NOTICE The
emergency shutoff controls are for USE ONLY BY
EMERGENCY. Do NOT use emergency shut-off devices
you control the normal stopping procedure.

The OEM may have equipped the application with a stop button.
emergency. For more information about the stop button
In case of emergency, consult the OEM information.

Make sure that all components of the external system that

we support the operation of the engine being held after the engine is
off.
Machine Translated by Google
SEBU7833-03 33
Operation section
Operation in cold weather

Operation in cold weather Install the correct engine oil specification before the
beginning of cold weather.

i02717265 Check all rubber parts (hoses, fan drive belts, etc.)

Operation in cold weather

weekly.

Check all electrical wiring and connections for wear or

damaged insulation.

Perkins diesel engines can operate efficiently in Keep all batteries fully charged and warmed up.
cold weather. During cold weather, the start and operation of
diesel engines depend on the following items: Fill the fuel tank at the end of each shift.

Check the air purifiers and the air intake daily.

The type of fuel used Check the air intake more frequently when operating in the snow.

The viscosity of the engine oil

Make sure that the glow plugs are in good working condition.
The operation of incandescent bulbs Refer to the Test and Adjustment Manual, 'Glow Plug - Test.'

Optional cold start assist

Battery condition

This section will cover the following information:

Personal injuries or property damage may result from
alcohol or starting fluids.

Potential problems caused by cold weather

Alcohol or starter fluids are highly flammable and toxic.
Operation
and if stored incorrectly, can result in injuries
or damages to property.
• Suggest measures that can be taken to
minimize start-up problems and operational issues when
the ambient air temperature is between 0° and -40 °C (32°
and 40 °F).

Do not use aerosol-type starting aids, such as ether. Such

The operation and maintenance of an engine at temperatures
use can result in explosion and personal injury.
coolants are complex. This occurs due to the following conditions:

Weather conditions • For auxiliary start with cables in cold weather,

refer to the Operation and Maintenance Manual, "Starting with
Applications of the engine Auxiliary Starting Cables. to obtain instructions.

The recommendations from the Perkins dealer or distributor

Perkins are based on proven practices from the past. The
Viscosity of Engine Lubrication
the information contained in this section provides guidelines for Oil
operation in cold weather.
The correct viscosity of the engine oil is essential. The viscosity
Does the oil affect the amount of torque needed to activate?
the engine. Consult this Operation and Maintenance Manual,
Tips for operating in cold weather
Fluid Recommendations to achieve the recommended viscosity
of the oil.
If the engine starts, operate the engine until a
minimum operating temperature of 81 °C (177.8 °F). Reach the
operational temperature will help prevent the valves from Recommendations for the soda
admission and escape grudem.
Provide protection to the cooling system for the smallest one.
expected external temperature. Refer to this Operation Manual and
The cooling system and the lubrication system Maintenance, "Fluid Recommendations" for the mixture of
because the engine does not lose heat immediately after shutdown. recommended soft drink.
This means that an engine can be turned off for a period.
of time and the engine may still have the ability to start
promptly.
Machine Translated by Google
34 SEBU7833-03
Operation section
Operation in cold weather

In cold climates, frequently check the fluid of The free operation of the valves is prevented.
cooling regarding the correct concentration of glycol for
ensure adequate protection against freezing. The valves get stuck.

Engine block heaters The rods can be bent.

Engine block heaters (if equipped) heat the Other damage to the valve train components may
result.
water from the engine shirt that surrounds the combustion chambers.
This provides the following functions:
For this reason, when the engine is started, it must be
The starting capacity is improved. operated until the coolant temperature is
from 71 °C (160 °F) at least. The carbon deposits on the rods
the valves will be kept to a minimum and the operation of the valves will be free
The heating time is reduced.
and the components of the valve will be maintained.

An electric heater in the block can be activated when the

the engine is turned off. An effective block heater is typically
a unit of 1250/1500 W. Consult the Perkins dealer Furthermore, the engine must be well heated to maintain the others.

or the Perkins distributor for more information. engine parts in better condition and the engine's lifespan will be
generally extended. The lubrication will be improved. There will be less
acid and less sludge in the oil. This will provide a longer lifespan
long for the engine bearings, the piston rings, and other parts.
Leaving the Engine at Idle
However, limit unnecessary downtime to ten minutes.
to reduce wear and unnecessary fuel consumption.
When idling after the engine starts in
cold weather, increase the engine speed from 1,000 to 1,200 rpm. This
will heat the engine faster.
Maintaining a high idle speed for long periods
it will be easier with the installation of a manual accelerator. The engine
The water temperature regulator is
it should not be 'accelerated' to speed up the heating process.
Insulated heating lines

The engine is equipped with a water temperature regulator.

While the engine is idling, applying a load When the engine coolant is below the
level (parasitic load) will help to reach the minimum temperature of correct operating temperature, the water in the jacket circulates through the block

operation. The minimum operating temperature is 82 °C (179.6 of the engine cylinders and into the engine head. The
°F). the refrigerant then returns to the cylinder block through a passage
internal that surrounds the valve of the temperature regulator of the

Recommendations for soda soda. This ensures that the soda flows around the engine in
cold operating conditions. The water temperature regulator
Heating it starts to open when the engine coolant reaches the
correct minimum operating temperature. As the
Warm up an engine that has cooled below operational temperatures the temperature of the cooling liquid in the sleeve rises above the
normal due to inactivity. This should be done before the engine minimum operating temperature, the water temperature regulator
return to full operation. During operation under conditions of opens even more, allowing more coolant to flow through
very low temperature, damage to the engine valve mechanisms the radiator dissipates excess heat.
may result from the operation of the engine for short intervals. This can
it will happen if the engine is turned on and off many times without being operated
to heat completely.
The progressive opening of the water temperature regulator operates
the progressive closure of the bypass passage between the block and
the head. This ensures the maximum flow of coolant to the
When the engine is operated below normal temperatures radiator, in order to achieve maximum heat dissipation.
operation, the fuel and the oil are not completely burned
in the combustion chamber. This fuel and oil cause the formation
of soft carbon deposits on the valve stems.
Generally, deposits do not cause problems and deposits are Note: Perkins discourages the use of all devices of
burned during the operation at normal temperatures of air flow restriction, like radiator blinds.
engine operation. Airflow restriction can result in the following: high temperatures
from exhaustion, loss of power, excessive use of the fan and
When the engine is turned on and off many times without being operated to reduction in fuel economy.
when completely heated, the carbon deposits become more
thick
This can cause the following problems:
Machine Translated by Google
SEBU7833-03 35
Operation section
Operation in cold weather

A cabin heater is beneficial in very cold climates. The supply When the Group 2 diesel fuels are used, the following
the motor and the cabin return lines must be isolated to reduce components provide a way to minimize problems in cold climates:
the loss of heat to the outside air.

Incandescent candles (if equipped)

Isolating the air intake and the engine

• Engine coolant heaters, which can be OEM
Compartment option

When temperatures below -18 °C (0 °F) are frequent

Fuel heaters, which can be an OEM option
found, an air filter inlet located in the compartment
the engine can be specified. An air filter located in the
Fuel line isolation, which can be an OEM option
the engine compartment can also minimize snow entry into the filter
from the air. In addition, the heat rejected by the engine helps to heat the air from
There are three main differences between the fuels of Group 1 and the
admission.
fuels of Group 2. The fuels of Group 1 have the following
different characteristics of Group 2 fuels.

Additional heat can be retained around the engine by insulating the compartment of the
A lower point of cloud
motor.

A lower melting point

i02322217
Higher energy per unit volume of fuel
Fuel and the effect of the cold
Climate Note: Group 3 fuels reduce the engine's lifespan. The use of
fuels of Group 3 are not covered by the Perkins warranty.

The fuels of Group 3 include Low Temperature Fuels and

Note: Only use fuel types recommended by Perkins. Consult
Aviation Kerosene Fuels.
this Operation and Maintenance Manual, "Fluid Recommendations".

Special fuels include biofuels.

The following fuels can be used in this series of engines.

The dew point is a temperature that allows the formation of crystals.
of wax in the fuel. These crystals can cause the clogging of the filters
of fuel.
Group 1

The fluidity point is the temperature when diesel fuel becomes

Group 2
thicken. Diesel fuel becomes more resistant to flow through the
fuel lines, fuel filters and fuel pumps.
Group 3

Be aware of these facts when purchasing diesel fuel. Consider the

Special Fuels
average ambient air temperature for engine application.
Engines that are fueled in one climate may not work well if
A Perkins prefers only Group 1 and Group 2 fuels for use
forests moved to another climate. Problems may arise due to changes
in this series of motors.
of temperature.

The fuels of Group 1 are the preferred Fuel Group for

general use of Perkins. Group 1 fuels maximize lifespan
Before troubleshooting low power or low performance
and engine performance. Group 1 fuels are generally
In winter, check the fuel to finish.
less available than the fuels of Group 2.
Frequently, Group 1 fuels are not available in
Low temperature fuels may be available for operation
colder climates during the winter.
of the engine at temperatures below 0 °C (32 °F). These fuels limit
the formation of wax in the fuel at low temperatures.
Note: Fuels from Group 2 must have a wear mark.
maximum of 650 micrometers (HFRR for ISO 12156-1).

For more information on operation in cold weather, consult the Manual of

The fuels in group 2 are considered acceptable for issues of
Operation and Maintenance, 'Operation in Cold Weather and Components
warranty. This group of fuels can reduce the lifespan of the engine, the
Related to Fuel in Cold Weather.
maximum engine power and engine fuel efficiency.
Machine Translated by Google
36 SEBU7833-03
Operation section
Operation in cold climate

i01903588

Components related to fuel in

Cold weather

Fuel tanks

Condensation can form in partially filled fuel tanks.

Fill the fuel tanks after operating the engine.

The fuel tanks must contain some provision for draining.

water and sediments from the bottom of the tanks.

Some fuel tanks use supply pipes that allow for the
water and the sediments settle below the end of the tube

fuel supply.

Some fuel tanks use supply lines.

that take the fuel directly from the bottom of the tank. If the engine
equipped with this system, regular maintenance of the filter of
the fuel system is important.

Drain the water and sediments from any storage tank

of fuel in the following intervals: weekly, exchanges of
oil and refueling of the fuel tank. This will help to avoid
that water and/or sediments are pumped from the tank of
fuel storage for the engine's fuel tank.

Fuel Filters

It is possible that a primary fuel filter is installed

between the fuel tank and the fuel inlet of the engine.
After replacing the fuel filter, always bleed the system.
fuel to remove air bubbles from the system of
fuel. Refer to the Operation and Maintenance Manual at
Maintenance Section for more information about
how to bleed the fuel system.

The classification of microns and the location of a primary filter of

Fuel is important in operation in cold weather. The filter
fuel primary and the fuel supply line are
the components most commonly affected by cold fuel.

Fuel Heaters

Note: The OEM can equip the application with heaters.

fuel. If that is the case, turn off an electric heater from
fuel in hot weather to prevent overheating of
fuel. If the type of fuel heater is a heat exchanger
Heat, the OEM should have included a bypass for hot weather.
Make sure the bypass is operational at all times.
hot to prevent the overheating of the fuel.

For more information about fuel heaters (if

equipped), consult the OEM information.
Machine Translated by Google
SEBU7833-03 37
Maintenance Section
Recharge capabilities

Maintenance Section Cooling system

To maintain the cooling system, the total capacity of

cooling system must be known. The capacity
Reloading capabilities approximately of the engine cooling system is
listed below. The capabilities of the external system vary between
the applications. Check the OEM specifications for the
i02198350
external system capacity. This capacity information
will be needed to determine the amount of soda/
Recharge capabilities
antifreeze necessary for the total cooling system.

Lubrication system
1104 Motor
Table 7

The capabilities of engine oil pan replenishment 1104 Natural Suction Motor
reflect the approximate capacity of the sump or sump plus the
standard oil filters. The auxiliary oil filter systems Compartment or System liters rooms
they will require additional oil. Refer to the OEM specifications for the 10.4 11
Only engine
capacity of the auxiliary oil filter.
Consult the Operation and Maintenance Manual, 'Section of External cooling system capacity
"Maintenance" for more information about the (OEM recommendation) (1)
Lubricant Specifications. Total cooling system (2)

(1) The external cooling system includes a radiator or a

1104 Motor expansion tank with the following components: heat exchanger,
post-cooler and piping. Refer to the OEM specifications. Insert the
Table 5 value for the external system capacity on this line.
(2) The Total Cooling System includes the system's capacity to
1104 Motor
engine cooling plus system capacity
Compartment or System Liters external cooling. Enter the total on this line.

Standard oil pan for the engine Table 8

6.5 7
carter (1)
1104 Turbocharged Engine
These values are the approximate capacities of the oil pan.
include the standard factory-installed oil filters. Compartment or System liters rooms
Engines with auxiliary oil filters require additional oil. Please refer to
Only engine 11.4 12
the OEM specifications for the capacity of the auxiliary oil filter.

Capacity of the external cooling system

(OEM recommendation) (1)
1103 Motor Total cooling system (2)
Table 6 The external cooling system includes a radiator or a
expansion tank with the following components: heat exchanger,
1103 Motor aftercooler and piping. Consult the OEM specifications. Insert the
Quarts value for the capacity of the external cooling system on this line.
Compartment or System
The Total Cooling System includes the capacity of the system to
Standard oil pan for the engine engine cooling plus the capacity of the system
6.5 7
carter (1) external cooling. Enter the total in this line.

These values are the approximate capacities of the crankcase,

includes the standard factory-installed oil filters.
Engines with auxiliary oil filters require additional oil. Please refer to
the OEM specifications for the capacity of the auxiliary oil filter.
Machine Translated by Google
38 SEBU7833-03
Maintenance Section
Recharging capabilities

1103 Motor Oils API

Table 9
The engine oil licensing and certification system of
1103 Natural aspiration engine without oil radiator American Petroleum Institute (API) is recognized by Perkins. For
to obtain detailed information about this system, consult
Compartment or System liters rooms
the latest edition of "Publication API No. 1509". Motor oils
Only engine 4.21 4 Those with the API symbol are authorized by the API.

Capacity of the external cooling system

(OEM recommendation) (1)

Total cooling system (2)

(1) The external cooling system includes a radiator or a

expansion tank with the following components: heat exchanger,
post-cooler and piping. Refer to OEM specifications. Insert
the value for the capacity of the external system in this line.
(2) The Total Cooling System includes the capacity of the system to
engine cooling system capacity
external cooling. Enter the total on this line.

Table 10

1103 Naturally Aspirated and Turbocharged Engines

Engines with oil radiator

Compartment or System liters rooms

Illustration 24 g00546535
Only engine 4.43 4.02
Typical API symbol
Cooling system capacity
(OEM recommendation) (1) The oils for CC, CD, CD-2, and CE diesel engines are not
classifications authorized by the API since January 1st
Total cooling system (2)
1996. Table 11 summarizes the situation of the classifications.
(1) The external cooling system includes a radiator or a
expansion tank with the following components: heat exchanger,
post-cooler and piping. Refer to OEM specifications. Insert Table 11
the value for the capacity of the external system in this line.
The Total Cooling System includes the capacity of the system to API Ratings
engine cooling plus the system capacity of
external cooling. Enter the total on this line. Current Obsolete

CF-4, CG-4, CH-4 THIS

i02280119 CF CC, CD
Fluid Recommendations CF-2(1) CD-2(1)

The CD-2 and American Petroleum Institute CF-2 classifications are for
two-stroke diesel engines. Perkins does not sell engines that
they use CD-2 and API CF-2 oils.
General Information about Lubricants
Terminology
Due to government regulations regarding certification
from engine exhaust emissions, the recommendations for Certain abbreviations follow the nomenclature of "SAE J754".
lubricants must be followed. Some classifications follow the abbreviations 'SAE J183' and
some classifications follow the 'EMA recommended guideline
for diesel engine oil.” In addition to the definitions from Perkins,
Association of Engine Manufacturers (EMA)
there are other definitions that will be useful in the purchase of lubricants.
oils
The recommended oil viscosities can be found
in this publication, topic 'Fluid/Oil Recommendations'
A Recommended Guideline from the Association of
Motor (Maintenance Section).
Manufacturers of Diesel Engine Oil
recognized by Perkins. For detailed information about
for this guideline, consult the latest edition of the EMA publication,
"EMA DHD -1"
Machine Translated by Google
SEBU7833-03 39
Maintenance Section
Recharge capabilities

Motor oil DHD-1 oils are recommended for use in programs of

extended oil change interval that optimizes the lifespan of
commercial oils oil. These oil change interval programs are
based on the oil analysis. DHD-1 oils are recommended
The performance of commercial oils for diesel engines for conditions that require premium oil. Your dealer or
is based on the ratings of the American Petroleum Perkins distributor has specific guidelines to optimize
Institute (API). These API classifications are developed for the oil change intervals.
provide commercial lubricants for a wide range of engines
a diesel that operate under various conditions. API CH-4 oils were developed to meet the
requirements of the new high-performance diesel engines. In addition
therefore, the oil was designed to meet the requirements of
Only use commercial oils that meet the following low emission diesel engines. The API CH-4 oils also
classifications: are acceptable for use in older diesel engines and in
diesel engines that use diesel fuel with high content of
Multigrade oil EMA DHD-1 (preferred oil) sulfur. API CH-4 oils can be used in engines
Perkins that use oils API CG-4 and API CF-4. The oils API CH-4
Multi-grade oil API CH-4 (preferred oil) they usually exceed the performance of API CG-4 oils in
following criteria: deposits in the pistons, control of consumption of
ACEAE3 oil, wear of the piston rings, wear of the valve train,
viscosity and corrosion control.
To make the correct choice of a commercial oil, consult the
following explanations:
Three new engine tests have been developed for the API oil.
CH-4. The first test specifically evaluates deposits in pistons
EMA DHD-1 – The Association of Engine Manufacturers
(EMA) developed lubricant recommendations for engines with two-piece steel pistons.
as an alternative to the API oil classification system. This test (piston deposit) also measures control of
DHD-1 is a Recommended Guideline that defines a level of oil consumption. A second test is conducted with soot
of moderate oil. The second test measures the following criteria:
performance of the oil for these types of diesel engines: high
speed, four-stroke cycle, heavy duty and light duty. wear of the piston rings, wear of the cylinder sleeves
DHD-1 oils can be used in Perkins engines when and resistance to corrosion. A third new test measures the
the following oils are recommended: API CH-4, API CG-4 and following characteristics with high levels of soot in the oil:
API CF-4. DHD-1 oils are designed to provide performance wear of the valve train, oil resistance to clogging the filter
superior compared to API CG-4 and API CF-4. of oil and sludge control.

In addition to the new tests, API CH-4 oils have stricter limits.

The DHD-1 oils will meet the needs of diesel engines. rigid for viscosity control in applications that generate high
High-performance Perkins that operate in many applications. soot theory. The oils also improved the resistance to
The tests and the test limits used to define DHD-1 are oxidation. API CH-4 oils must pass a test
similar to the new classification API CH-4. Therefore, these additional (piston deposit) for engines that use pistons
made of aluminum (single piece). The performance of the oil is also
oils will also meet the requirements for diesel engines
that require low emissions. The DHD-1 oils are designed for established for engines operating in areas with
control the harmful effects of soot with greater resistance to diesel fuel with high sulfur content.
wear and greater resistance to oil filter clogging.
All these improvements allow the oil API CH-4
These oils also provide superior control of deposits ideal oil change interval ranges. API CH-4 oils
they are recommended for use during prolonged exchange intervals
piston for engines with two-piece steel pistons or pistons
of aluminum. of oil. API CH-4 oils are recommended for conditions
that require a premium oil. Your dealer or distributor
All DHD-1 oils must complete a testing program. Perkins has specific guidelines to optimize the intervals of
complete with the base oil and with the viscosity grade of the oil oil change.
finished commercial. The use of 'Base oil exchange guidelines'
Some commercial oils that meet the classifications
"API" is not suitable for DHD-1 oils. This feature reduces the
variation in performance that can occur when the stocks APIs may require shorter oil change intervals.
Basics are altered in commercial oil formulations. determine the oil change interval, closely monitor the condition
from the oil and perform a wear metal analysis.
Machine Translated by Google
40 SEBU7833-03
Maintenance Section
Charging capabilities

Table 12
NOTICE
Percentage of sulfur in the Oil change interval
failure to follow these oil recommendations can reduce lifespan
fuel
engine useful due to deposits and/or excessive wear.
Less than 0.5 Normal

0.5 to 1.0 0.75 of normal

Total Base Number (TBN) and Fuel Sulfur Greater than 1.0 0.50 to normal
Levels for Direct Injection Diesel (DI)
Engines Lubricant viscosity recommendations
for direct injection (DI) diesel engines
The Total Base Number (TBN) for an oil depends on the level of
sulfur from the fuel. For direct injection engines that use
The correct SAE viscosity grade of the oil is determined by
distillate fuel, the minimum TBN of the new oil must be 10
minimum ambient temperature during engine start
times the level of sulfur in the fuel. The TBN is defined by
cold and by the maximum ambient temperature during operation
"ASTM D2896". The minimum TBN of the oil is 5, regardless of of the motor.
sulfur level of the fuel. Illustration 25 demonstrates the TBN.

Refer to Table 13 (minimum temperature) to determine the

oil viscosity needed to start a cold engine.

Refer to Table 13 (maximum temperature) to select the

oil viscosity for engine operation at temperature
higher forecast environment.

Generally, use the oil with the highest viscosity available.

to meet the temperature requirements at startup.

Table 13

Viscosity of the motor oil

g00799818 EMA LRG-1 Ambient temperature

Illustration 25
API CH-4
Minimum Maximum
(Y) TBN for "ASTM D2896" Viscosity Degree
Percentage of sulfur in the fuel by
weight (1) Oil TBN SAE 0W20 -40 °C (-40 °F) 10°C (50°F)
Change the oil when the TBN deteriorates to 50 percent of the TBN.
SAE 0W30 -40 °C (-40 °F) 30°C (86°F)
original.

SAE 0W40 ÿ40 °C (ÿ40 °F) 40 °C (104 °F)

Use the following guidelines for fuel sulfur levels
that exceed 1.5 percent: SAE 5W30 ÿ30 °C (ÿ22 °F) 30°C (86°F)

SAE 5W40 ÿ30 °C (ÿ22 °F) 40 °C (104 °F)

Choose an oil with the highest TBN that meets one of these
classificações: EMA DHD-1 e API CH-4. SAE 10W30 -20 °C (-4 °F) 40°C (104°F)

SAE 15W40 10 °C (14 °F) 50°C (122°F)

• Reduce the oil change interval. Base on the oil
exchange interval in oil analysis. Make sure that the
oil analysis includes the condition of the oil and a metal analysis Synthetic base oil
of wear.
Synthetic base oils are acceptable for use in these
Excessive deposits on the piston may be caused by an oil motors if these oils meet the performance requirements
with a high TBN. These deposits can lead to loss of control specified for the engine.
of oil consumption and to the polishing of the cylinder hole.
Synthetic base oils generally perform better
than conventional oils in the two areas below:
NOTICE TO
Synthetic base oils have improved flow at low temperatures.
operation of direct injection (DI) diesel engines with levels of
temperatures, especially in Arctic conditions.
fuel sulfur above 0.5 percent will require intervals of
reduced oil changes to help maintain protection against
Synthetic base oils have improved oxidation.
appropriate wear.
stability especially at high operating temperatures.
Machine Translated by Google
SEBU7833-03 41
Maintenance Section
Recharge capabilities

Some synthetic base oils have characteristics of

performance that increases the oil lifespan. Perkins does not NOTICE TO
automatic extension of the exchange intervals is recommended
the engine's lifespan can be reduced if oils are used from
from oil to any type of oil. second choice.

Rerefined base oil Aftermarket oil additives

Perkins does not recommend the use of replacement additives in

The rerun base oil is acceptable for use in engines.
oil. It is not necessary to use replacement additives to achieve the
Perkins if these oils meet the requirements of
maximum useful life of the engine or the nominal performance. The oils
performance specified by Perkins. The rerefined base oil
fully formulated finishes consist of base oils
can be used exclusively on finished oil or on
and in packages of commercial additives. These packages of additives
combination with new basic oil. The military specifications
from the USA and the specifications of other manufacturers of
are mixed with the base oils in precise percentages
to help provide finished oils with characteristics of
heavy equipment also allows the use of base oil
re-refined that meets the same criteria. performance that meets industry standards.

The process used to manufacture reraffinated base oil must

There are no standard industry tests that assess performance.
properly remove all wear metals that
are in the used oil and all the additives that are in the oil or the compatibility of aftermarket additives in finished oil.
Replacement market additives may not be
used. The process used to make reruned base oil
compatible with the finished oil additives package,
usually involves the vacuum distillation process and
that can decrease the performance of the finished oil. The additive
hydro-treatment of used oil. Filtration is suitable for the
the replacement market may not mix with the oil
high-quality rerefined base oil production.
finished. This can produce sludge in the sump. The Perkins
discourages the use of replacement additives in oils
finishes.
Lubricants for cold weather
To achieve the best performance from a Perkins engine, follow
When an engine is started and an engine is operated at temperatures
the following guidelines:
environments below -20 °C (-4 °F), use multigrade oils
that are able to flow at low temperatures. Select the correct oil or a commercial oil that meets the
Recommended guideline from EMA for motor oil
"diesel" or the recommended API classification.
These oils have lubricant viscosity grades of SAE
0W or SAE 5W.
• Consult the appropriate "Lubricant Viscosities" table
to find the correct viscosity grade of the oil for the
When an engine is started and operated at ambient temperatures your engine.
below ÿ30 °C (ÿ22 °F), use a synthetic multi-grade oil
base with a viscosity grade of 0W or with a grade of • In the specified interval, perform engine maintenance. Use
viscosity 5W. Use an oil with a lower flow point than new oil and install a new oil filter.
-50 °C (-58 °F)
Perform maintenance at the specified intervals in
The number of acceptable lubricants is limited under conditions Operation and Maintenance Manual, "Schedule of
for cold weather. Perkins recommends the following lubricants
Maintenance Intervals.
for use in cold climates:

First Choice – Use oil with a Guideline Oil Analysis S·O·S

Recommended EMA DHD-1. Use a CH-4 oil that has
an API license. The oil must have a lubricating viscosity grade Some engines can be equipped with a valve of
SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30 or SAE 5W40. oil sampling. If the S·O·S oil analysis is necessary,
the oil sampling valve is used to obtain samples from the
engine oil. The S·O·S oil analysis will complement the
Second choice – Use an oil that has a package preventive maintenance program.
of CH-4 additives. Although the oil has not been tested
The S·O·S oil analysis is a diagnostic tool used
for the API license requirements, the oil must be SAE 0W20,
SAE 0W30, SAE 0W40, SAE 5W30 or SAE 5W40. to determine the performance of the oil and the wear rates
two components. Contamination can be identified and measured
through the use of oil analysis S·O·S. The S·O·S oil analysis
includes the following tests:
Machine Translated by Google
42 SEBU7833-03
Maintenance Section
Charging capabilities

The wear rate analysis monitors the wear of metals from The high sulfur content of the fuel is not normally found
motor. The amount of wear metal and the type of metal of in Europe, North America or Australasia. This can cause
wear that is in the oil is analyzed. The increase in the metal rate engine wear. When only fuels with high content of
engine wear in the oil is just as important as the quantity if sulfur is available, it will be necessary to use lubricating oil
metal wear from the engine in the oil. highly alkaline in the engine or reduce the replacement interval of
lubricating oil.

Tests are conducted to detect Distillation

oil contamination by water, glycol or fuel.
This is an indication of the mixture of different hydrocarbons
The Oil Condition Analysis determines the loss of properties no fuel. A high proportion of light hydrocarbons can
oil lubricants. An infrared analysis is used for comparison affect the characteristics of combustion.
the properties of the new oil with the properties of the sample of
used oil. This analysis allows technicians to determine the
amount of oil deterioration during use. This analysis Lubricity
also allows technicians to check the oil performance
according to the specification throughout the exchange interval This is the fuel capacity to prevent pump wear.
oil.
Diesel engines have the ability to burn a wide variety
of fuels. These fuels are divided into four groups

Fuel Specifications general

Group 1 (preferred fuels)

Fuel Recommendations
Group 2 (allowed fuels)
To obtain the correct power and performance of the engine, use a
correct quality fuel. The fuel specification Group 3 (aviation kerosene)
recommended for Perkins engines is shown below:
Other fuels

• Cetane number ____________________ minimum of 45

Group 1 (preferred fuels): Specification

2.0 to 4.5 cSt at 40 °C (104 °F) DERV for EN590

0.835 to 0.855 Kg/liter Note: Use only arctic fuels when the temperature
is below 0 °C (32 °F). Do not use Arctic fuels when the
• Sulfur_______________________0.2% by mass, maximum ambient temperature is above 0 °C (32 °F). To ensure that the
time period between the engine start and the first ignition should be
Distillation________________85% at 350 °C (662 °F) minimum, use only fuel with the correct viscosity and in
correct temperature.
Lubricity
maximum of 460 micrometers in 'ISO 12156 - 1' Gas oil for 'BS2869 Class A2'

cetane number
ASTM D975 - 91 Class 2D can only be used if the fuel has the
correct specification of lubricity.
This indicates the ignition properties of the fuel.
Fuel with a low cetane number may be the root cause
"JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3" can only be used
of problems during the cold start. This will affect the combustion. if the fuel has the correct lubricity specification.

Viscosity Note: If aromatic fuels with low sulfur content are used

or with low sulfur content, fuel additives can be used to

This is the resistance to the flow of a fluid. If this resistance
increase lubricity.
is outside the limits, the engine and the engine start performance
in particular may be affected. Group 2 (allowed fuels): Specification

These fuel specifications are considered acceptable for

Sulfur
warranty issues. However, these fuels may
reduce the engine's lifespan, the engine's maximum power, and efficiency
of the engine's fuel.
Machine Translated by Google
SEBU7833-03 43
Maintenance Section
Charging capabilities

ASTM D975 - 91 Class 1D The preferred fuels provide maximum lifespan and performance.
for motors. The preferred fuels are distilled fuels. These
JP7, Mil T38219 fuels are commonly called diesel oil or gas oil.

NATO F63
The allowed fuels are crude oils or blended fuels.
NOTICE The use of these fuels can result in maintenance costs
These fuels should have a wear and tear brand value of no higher and in the reduction of the engine's lifespan.
maximum 650 micrometers *HFRR for ISO 12156 - 1.*
The diesel fuels that meet the specifications of the Table
14 will help to provide maximum lifespan and engine performance.
Group 3 (aviation kerosene): Specification
In North America, the diesel fuel identified as No. 2-D
In "ASTM D975" generally meets the specifications. Table 14
These fuels need additives to achieve a lubricity of
it is for diesel fuels distilled from crude oil. Fuels
650 micrometers of wear scar and the reliability of the pump diesel from other sources may exhibit harmful properties that
the fuel injection will be reduced. The injection pump of
are not defined or controlled by this specification.
fuel is not covered by the warranty, even with additives
included.
Table 14
JP5 MIL T5624 (Avcat FSII, NATO F44)
Perkins specifications for distilled diesel fuel
JP8 T83133 (Aviation fuel FSII, NATO F34) Specifications Requirements ASTM Test

Jet A Aromatic maximum of 35% D1319

maximum 0.02%
Ashes D482
Jet A1, NATO F35, XF63 (weight)
Carbon residue 0.35% maximum
Low temperature fuels D524
in funds of 10% (weight)

Special fuels for use in cold weather may be available 40 minimum (engines
Cetane number D613
for engine operation at temperatures below 0 °C (32 °F). DI)
These fuels limit the formation of wax in the fuel oil in
The point of
low temperatures. If the wax forms in the fuel oil, this
It can interrupt the flow of fuel oil through the filter. mist should not
exceed to -
cloud point
temperature
Note: These fuels with a lack of lubrication can cause the environment
following problems: lower expected.
(continuous)
Low engine power

Difficult match in hot or cold conditions

White smoke

Deterioration of emissions and ignition failure under certain conditions

operational

Biomass fuel: Specification

Biofuel: A mixture of 5% RME for EN14214 is permitted.

conventional fuel.

PERCEIVE
Water emulsion fuels: These fuels are not allowed

Consult the following fuel specifications for the

North America.
Machine Translated by Google
44 SEBU7833-03
Maintenance Section
Recharging capabilities

(Table 14, continuation)

No. 3 maximum NOTICE

Copper strip D130
Corrosion Operate with fuels that do not meet the recommendations of
Perkins can cause the following effects: Difficulty starting,
10% at 282 °C (540
poor combustion, deposits in the fuel injectors, lifespan
°F) no
maximum reduced from the fuel system, deposits in the combustion chamber
Distillation D86 and vice-versa of the engine.
90% at 360 °C (680
°F) no
maximum
NOTICE
Flash point legal limit D93
Heavy fuel oil (HFO), residual fuel or fuel
30 minimum mixed should NOT be used in Perkins diesel engines. The wear
Gravity API D287
45 at most serious and the failures of the components will occur if the fuels of the type
HFO was used in engines configured to use fuel
Minimum of 6 °C distilled.
10 °F
For Item D97
below the
ambient temperature In extremely cold environmental conditions, you can use the
distillate fuels specified in Table 15. However, the
0.2% maximum D3605
the selected fuel must meet the specified requirements in the
Sulfur (1) or
Table 14. These fuels should be used in
D1552
operational temperatures low to -54 °C (-65 °F).
2.0 cSt minimum and 4.5
Cinematic maximum cSt to
D445
Viscosity (2) 40 °C (104 °F) Table 15

Distilled Fuels(1)
Water and 0.1% maximum
D1796 Specification Note
Sediment
MIL-T-5624R JP-5
Water 0.1% maximum D1744
ASTM D1655 Jet-A-1
0.05% maximum (weight)
Sediment D473
MIL-T-83133D JP-8

Gums and Resins (3) 10 mg per 100 mL (1) The fuels listed in this table may not meet the
D381
at most requirements specified in the Table 'Perkins Specifications for Diesel Fuel
Distillate. Consult the supplier about the recommended additives to maintain the
Maximum of correct fuel lubricity.

0.38 mm (0.015 D6079

Lubricity (4)
at 25 °C (77
°F) These fuels are lighter than fuel grade no. 2.
The fuel systems and engine components of Perkins can operate
The cetane number of the fuels in Table 15 must be at least
with fuels that have a high sulfur content. The sulfur levels of minimum 40. If the viscosity is less than 1.4 cSt at 38 °C (100 °F), use
fuel affects exhaust emissions. Fuels with high the fuel only at temperatures below 0 °C (32 °F). Not
sulfur compounds also increase the corrosion potential of the components
use fuels with a viscosity lower than 1.2 cSt at 38 °C (100 °F).
internals. Fuel sulfur levels above 0.5 percent can shorten
significantly the oil change interval. For additional information, please consult The cooling of the fuel may be necessary to maintain the
this publication, topic 'Recommendations for Fluids/Oil of the Engine' (Maintenance Section). minimum viscosity of 1.4 cSt in the fuel injection pump.
(2) The viscosity values of the fuel are the values as the fuel
is provided to the fuel injection pumps. If a fuel with is used
low viscosity, it may be necessary to cool the fuel to maintain a viscosity
There are many other specifications for diesel fuel that are
from 1.4 cSt in the fuel injection pump. Fuels with high viscosity can
require fuel heaters to reduce viscosity to a viscosity of published by governments and by technology societies. Normally,
20 cSt. these specifications do not review all the requirements addressed
Follow the testing conditions and procedures for gasoline (engine). in this specification. To ensure the optimal performance of the engine,
A fuel's lubricity is a concern with low sulfur content fuel. a complete analysis of the fuel must be obtained before the
To determine the lubricity of the fuel, use the "ASTM D6078 Scuffing Load" test.
engine operation. The fuel analysis must include all the
Wear Test (SBOCLE) or the test "ASTM D6079 High Frequency Reciprocating Rig (HFRR)".
If the lubricity of a fuel does not meet the minimum requirements, consult your
properties listed in Table 14.
fuel supplier. Do not handle the fuel without consulting the supplier.
fuel. Some additives are not compatible. These additives can cause
problems in the fuel system.
Machine Translated by Google
SEBU7833-03 45
Maintenance Section
Recharge capabilities

Cooling system specifications DO NOT use the following types of water in cooling systems:
Hard water, softened water that has been conditioned with salt and water
General Information about the Soda of the sea.

If distilled water or deionized water is not available, use

NOTICE
water with the properties listed in Table 16.
Never add coolant to an overheated engine.
Damage to the engine may occur. Let the engine cool down first.
Table 16

NOTICE If Minimum acceptable water requirements of Perkins

the motor to be stored or sent to an area with temperatures Maximum Limit
Property
below zero, the cooling system must be protected for the
lower external temperature or completely drained to Chloride (Cl) 40 mg/L
avoid damage.
Sulfate (SO4) 100 mg/L
Total hardness 170 mg/L
NOTICE
Total solids 340 mg/L
Check the specific gravity of the coolant frequently.
for proper protection against freezing or protection against boiling. Acidity pH from 5.5 to 9.0

Clean the cooling system for the following reasons: For a water analysis, consult one of the following
sources:
Contamination of the cooling system
Local water supply company
Engine overheating
Agricultural agent
Soda foam
Independent laboratory
NOTICE
Never operate an engine without water temperature regulators.
additives
cooling system. The water temperature regulators
help maintain the engine coolant at the temperature The additives help protect the metal surfaces from
adequate operational. Problems in the cooling system may cooling system. The lack of refrigerant additives or
to develop without the water temperature regulators. insufficient amounts of additives allow for the occurrence of the
following conditions:

Corrosion
Many engine failures are related to the system of
cooling. The following problems are related to failures
Formation of mineral deposits
in the cooling system: Overheating, leakage of
water pump and clogged radiators or heat exchangers. Rust

These failures can be avoided with proper maintenance of Scale

cooling system. The maintenance of the cooling system
is just as important as the maintenance of the fuel system and
Foam from the soda
of the lubrication system. The quality of the coolant is so
as important as the quality of the fuel and lubricating oil.
Many additives are depleted during engine operation.
These additives should be replaced periodically.

The soft drink is usually composed of three elements: water, The additives must be added in the correct concentration.
additives and glycol. The superconcentration of additives can cause the
inhibitors come out of the solution. The deposits may allow for
Water occurrence of the following problems:

Water is used in the cooling system to transfer Formation of gel compounds

heat.
Reduction of heat transfer
Distilled water or deionized water is recommended
for use in engine cooling systems. Water pump sealing leak

Obstruction of radiators, coolers, and small passages

Machine Translated by Google
46 SEBU7833-03
Maintenance Section
Charging capabilities

glycol Acceptable - A commercial refrigerant/antifreeze

for heavy service that meets the specifications 'ASTM'
The glycol in the refrigerant helps provide protection against the D4985
following conditions:
NOTICE
boiling Do not use commercial refrigerant/antifreeze that only meets the
ASTM D3306 specification. This type of coolant/antifreeze is
Freezing
made for light automotive applications.

Cavitation of the water pump

Perkins recommends a 1:1 mixture of water and glycol.

For optimal performance, Perkins recommends a 1:1 mixture.
of a water/glycol solution. This mixture of water and glycol will provide excellent performance.
heavy-duty like refrigerant/coolant. This
Note: Use a mixture that provides protection against the the proportion can be increased to 1:2 of water to glycol if it is
lower ambient temperature. extra protection against freezing is necessary.

Note: 100% pure glycol freezes at a temperature Note: A commercial coolant/antifreeze for service
-23 °C (-9 °F) heavy that meets the specifications 'ASTM D4985' MAY require a
treatment with an SCA during initial refueling. Read the label or

Most conventional coolants/antifreezes use the instructions provided by the product OEM.
ethylene glycol. Propylene glycol can also be used. In a
a 1:1 mixture with water, ethylene and propylene glycol provide
protection similar against freezing and boiling. In stationary engine applications and motor applications
Consult Tables 17 and 18. maritime that do not require anti-boil protection or protection
against freezing, a mixture of SCA and water is acceptable. The
Table 17 Perkins recommends a concentration of six percent to eight percent.
hundred of SCA in these cooling systems. Distilled water
Ethylene glycol
or deionized water is preferred. Water with can be used.
Freeze Fervor recommended properties.
Concentration
Protection Protection

50 percent ÿ36 °C (ÿ33 °F) 106 °C (223 °F)

The motors that operate at ambient temperatures above 43 °C
60 percent ÿ51 °C (ÿ60 °F) 111 °C (232 °F) (109.4 °F) must use SCA and water.
Motors operating at ambient temperatures above 43 °C
(109.4 °F) and below 0 °C (32 °F) due to seasonal variations,
NOTICE
consult the Perkins dealer or Perkins distributor for more information
Do not use propylene glycol in concentrations that exceed 50 percent.
the correct level of protection.
of glycol due to the reduced heat transfer capacity of
propylene glycol. Use ethylene glycol under conditions that require protection
additional against boiling or freezing. Table 19

Shelf life of the soda

Table 18 Type of refrigerant Service life

Propylene glycol 12,000 hours of service or

Perkins ELC
six years
Freeze antipyretic
Concentration
Protection Protection Heavy Commercial Service 3000 hours of service or
Coolant liquid/
50 percent Two years
ÿ29 °C (ÿ20 °F) 106 °C (223 °F) antifreeze that meets 'ASTM D4985'

Perkins POWERPART 3000 hours of service or

To check the concentration of glycol in the coolant, measure the SCA Two years
specific gravity of the refrigerant.
Commercial SCA and 3000 hours of service or
Water Two years
Recommendations for soda

The two coolants used in Perkins diesel engines are: Extended Life Coolant (ELC)

Perkins provides extended life coolant (ELC) for

Preferred – Perkins Extended Life Coolant (ELC) used in the following applications:

Spark ignition gas engines for heavy-duty service

Machine Translated by Google
SEBU7833-03 47
Maintenance Section
Reloading capabilities

Heavy-duty diesel engines

NOTICE No
Automotive applications use a conventional refrigerant liquid to complete a system of
cooling system filled with Extended Life Coolant (ELC).
The anticorrosive package for ELC is different from the anticorrosive package.
for other refrigerants. ELC is a refrigerant based on Do not use standard supplemental refrigerant additive (SCA). Use
ethylene glycol. However, the ELC contains corrosion inhibitors only the ELC Extender in cooling systems that are
organic and antifoaming agents with low amounts filled with ELC.
of nitrite. The Perkins ELC was formulated with the amount
correctness of these additives to provide superior protection against
corrosion for all metals in cooling systems Perkins ELC Extender
motor.
The ELC Extender is added to the cooling system in
The ELC extends the lifespan of the coolant to 12,000 hours. half of the useful life of the ELC. Treat the cooling system with
service or six years. The ELC does not require a frequent addition. ELC Extender in 6,000 hours or three years. Use Table 20 for
of a Supplementary Additive for Soft Drink (SCA). A determine the correct amount of ELC Extender needed.
extensor is the only additional maintenance required at 6,000
service hours or half of the useful life of the ELC.
Containers of various sizes are available. Please consult the
Perkins reseller or the Perkins distributor to obtain the numbers
The ELC is available in a pre-cooling solution. of piece.
mixed 1:1 with distilled water. The pre-mixed ELC
provides freeze protection down to -36 °C (-33 °F). The Use the formula in Table 20 to determine the correct quantity.
ELC pre-mixed is recommended for the initial filling of the from ELC Extender for your cooling system.
cooling system. The pre-mixed ELC is also Consult the Operation and Maintenance Manual, "Capabilities of
recommended to complete the cooling system. "Replenishment" to determine the capacity of the system
cooling.
ELC Concentrate is also available. The ELC Concentrate
can be used to reduce the freezing point to -51 Table 20

°C (ÿ60 °F) in Arctic conditions. Formula to add the ELC extender to the ELC

Containers of various sizes are available. Please consult the V × 0.02 = X

Perkins dealer or the Perkins distributor to obtain the numbers V is the total capacity of the refrigeration system.
of piece.
X is the amount of ELC Extender needed.

Cooling system maintenance ELC

Table 21 is an example of the use of the formula that is in the Table
20.
Correct additions to Extended Life
soda Table 21

Example of the equation to add ELC

NOTICE Extensor for ELC
Use only Perkins products for pre-mixed soft drinks or
Total volume Multiplication Quantity of ELC
concentrated.
of cooling Factor What is an extensor

System (V) Necessary (X)

Use only Perkins Extender with long-life refrigerant fluid.
extended. 0.18 L
9 L (2.4 US gal) × 0.02 (0.05 US gal) or
The mixture of long-lasting soda with other products (6 fl oz)
reduces the shelf life of long-lasting soda. The not
compliance with recommendations can reduce the lifespan of NOTICE To
cooling system components, unless an action use Perkins ELC, do not use SCA filters or standard SCA.
appropriate corrective action is taken.

To maintain the correct balance between the antifreeze and the

additives, you should maintain the recommended concentration of
Extended Life Coolant (ELC). Decrease
the proportion of antifreeze decreases the proportion of additive. This
it will decrease the ability of the refrigerant to protect the system
against corrosion, cavitation, erosion and deposits.
Machine Translated by Google
48 SEBU7833-03
Maintenance Section
Reloading capabilities

Cleaning of the ELC Cooling System

NOTICE TO
Note: If the cooling system is already using ELC, do not incorrect or incomplete flushing of the cooling system may
it is necessary to use cleaning agents during the replacement interval result in damage to copper and other metal components.
specified refrigerant. Cleaning agents are necessary
only if the system has been contaminated by the addition of
some other type of soda or damage to the system of To avoid damage to the cooling system, make sure to wash
cooling. it completely with clean water.
Continue to wash the system until all signals from the agent are
Clean water is the only cleaning agent needed when the ELC cleaning disappears.
is drained from the cooling system.

After the cooling system has been drained and after Drain the cooling system into a suitable container and
if the cooling system needs to be refilled, operate the engine clean the cooling system with clean water.
while the coolant system fill cap
is removed. Operate the engine until the level of the coolant liquid Note: The coolant system cleaner must be completely
maintain the normal operating temperature and until the level of cooling system flush. The system cleaner of the
coolant stabilizes. Add as necessary, cooling left in the system will contaminate the liquid
the mixture of soda to fill the system to the specified level. cooling. The washer can also corrode the system of
cooling.

Moving to Perkins ELC

8. Repeat steps 6 and 7 until the system is
completely clean.
To switch from heavy-duty refrigerant/antifreeze to the
Perkins ELC, execute the following steps:
9. Fill the cooling system with Perkins Premixed
ELC.
NOTICE
Care must be taken to ensure that all fluids are
Contamination of the ELC cooling system
contents during the execution of inspection, maintenance, testing, adjustment
the product repair. Be prepared to collect the fluid with
NOTICE TO
suitable containers before opening any compartment or
dismantle any component that contains fluids. mixing ELC with other products reduces the effectiveness of ELC and diminishes
the useful life of the ELC.

Only use Perkins products for pre-mixed soft drinks or

Dispose of all fluids in accordance with regulations and mandates. concentrated. Only use the Perkins ELC extender with Perkins ELC.
places. The non-compliance with these recommendations may result in the reduction

of the lifespan of the components of the cooling system.

1. Drain the soda into a suitable container.

[Link] the soda according to the regulations The ELC cooling systems can withstand contamination up to
places. a maximum of ten percent of the coolant/antifreeze
conventional for heavy service or SCA. If the contamination
3. Wash the system with clean water to remove any exceed ten percent of the system's total capacity, execute
debris. One of the following procedures:

4. Use the Perkins cleaner to clean the system. Follow Drain the cooling system into a suitable container.
the instruction on the label. Dispose of the soda according to the regulations.
locations. Wash the system with clean water. Fill the system with the
[Link] the cleaner into a suitable container. Wash the system of Perkins ELC.
cooling with clean water.
Drain a part of the cooling system into a container
[Link] the cooling system with clean water and adequate according to local regulations. Then,
operate the engine until it is warmed up to 49° to 66°C (120° to fill the cooling system with pre-mixed ELC. This
150°F. it must reduce pollution to less than 10%.

Keep the system as a conventional soft drink for service

heavy. Treat the system with an SCA. Replace the soda in
recommended interval for conventional soda for
heavy service.
Machine Translated by Google
SEBU7833-03 49
Maintenance Section
Reloading capabilities

Commercial Heavy Cooling Liquid Table 24 is an example to use the equation that is in the
Antifreeze and SCA Table 23.

Table 24
NOTICE
Commercial coolant for heavy-duty service that contains Example of the equation to add the SCA to
The heavy-duty coolant for initial fueling
Amina, as part of the corrosion protection system, should not
to be used. Total Volume of Multiplication Quantity of SCA
Cooling Factor necessary
System (V) (X)
NOTICE
× 0.045 0.7 L (24 ounces)
Never operate an engine without water temperature regulators. 15 L (4 American gallons)

cooling system. The water temperature regulators

they help keep the engine coolant at temperature
Adding the SCA to heavy-duty service
correct operation. Problems in the cooling system can
to develop without the water temperature regulators.
Refrigerant for Maintenance

Coolant/antifreeze for heavy-duty service of all types

REQUIRE periodic increments of a SCA.
Check the refrigerant/antifreeze (glycol concentration)
to ensure adequate protection against boiling or
Test the refrigerant/antifreeze periodically as to how much
freezing. Perkins recommends the use of a refractometer to to the concentration of SCA. For the interval, consult the Manual of
check the glycol concentration.
Operation and Maintenance, "Interval Schedule of
Maintenance (Maintenance Section). Test the concentration of
The cooling systems of the Perkins engine must be SCA.
tested at intervals of 500 hours for the concentration
of Supplemental Coolant Additive (SCA). The additions of SCA are based on the test results.
the size of the cooling system determines the amount of
SCA additions are based on test results.
SCA required.
A liquid SCA may be required at intervals of 500 hours.
Use the equation in Table 25 to determine the quantity
of Perkins SCA necessary, if necessary:
Refer to Table 22 for part numbers and quantities of
SCA. Table 25

Table 22 Equation to add the SCA to heavy service

Refrigerant for Maintenance
Perkins Liquid SCA
V × 0.014 = X
Part number Quantity
V is the total volume of the cooling system.
21825735
X is the amount of SCA required.

Adding the SCA to the service coolant

Table 26 is an example to use the equation that is in the
heavy on initial supply Table 25.

The commercial coolant/antifreeze for service Table 26

heavy that meets the specifications 'ASTM D4985' CAN
Example of the equation to add the SCA to
demand the addition of SCA in the initial supply. Read the label or
The heavy-duty coolant for maintenance
the instructions provided by the product OEM.
Total Volume of Multiplication Quantity of SCA
Cooling Factor necessary
Use the equation from Table 23 to determine the quantity of System (V) (X)
Perkins SCA needed when the cooling system is 15 L (4 American gallons) × 0.014 0.2 L (7 ounces)
initially supplied.

Table 23

Equation to add the SCA to heavy service

Refrigerant in initial filling

V × 0.045 = X

V is the total volume of the cooling system.

X is the amount of SCA required.

Machine Translated by Google
50 SEBU7833-03
Maintenance Section
Refueling capabilities

Cleaning the Heavy Service System

Refrigerant/Antifreeze

The cooling system cleaners of Perkins are

designed to clean the cooling system of deposits
harmful and corrosion. The cooling system cleaners
from Perkins dissolve mineral deposits, corrosion products,
contamination by light oil and sludge.

Clean the cooling system after the used coolant is drained.

drained or before the cooling system is refilled with new
coolant.

Always clean the cooling system whenever the refrigerant fluid is

contaminated or whenever the refrigerant liquid is foaming.
Machine Translated by Google
SEBU7833-03 51
Maintenance Section
Maintenance Interval Schedule

i03302982 Every 2 years

Maintenance Interval Schedule Cooling System Coolant - Change ........................ 58

Every 3000 hours of service

When requested Fuel Injector - Test/Change ...................... 68

Battery - Replace .............................................. ... 54 Battery or Cable of Every 3,000 hours of service or 2 years
Battery - Disconnect ............... 55 Engine -
Clean ............... ......................................... 60 Air Filter Element of Cooling Liquid of the Cooling System (Commercial Heavy-
Motor (Double Element) - Clean/ Duty) - Exchange ....................................... ...................... 55
Replace . ................................................ 61 Air Filter Element of
Motor (Simple Element) - Inspect/Replace ....................... ............. Every 4000 hours of service
63 Engine oil sample - Obtain .............................. .... 64 Injector of
Post-cooler core - Clean/Test ...................... 52
Fuel - Test/Replace ..................... 68 Fuel System -
Prime ............................... 69 Application of Serious Services -
Check .................... 75
Every 6,000 hours of service or 3 years

Coolant system extension (ELC) - Add .... 59

Diary
Every 12,000 hours of service or 6 years
Alternator and fan belts - Inspect/Adjust/
Coolant of the Cooling System (ELC) - Change .......... 57
Replace ...................................... ...................... 53 Liquid level
coolant of the cooling system - Check .............. 59 Equipment
activated - Check .............................. 60 Maintenance indicator of
engine air filter - Inspect ..... 63 Engine oil level -
Check ...................................... 64 Primary filter of the system
fuel / Water Separator -
Drainage Inspection 70
general ............... ................ 77

Every 50 hours of service or weekly

Fuel Tank Water and Sediments - Drain .............. 73

Every 500 hours of service or 1 year

Battery Electrolyte Level - Check ....................... 54 Element of

Engine Air Filter (Dual Element) - Clean/
Replace ...... ......................................... 61 Engine air filter Element
(Unique Element) - Inspect/Replace
63 Engine Solo - Inspect/Clean ....................... 64 Oil and Filter of
Engine - Change ...................... 65 Primary Fuel System Filter
Water Separator

Element - Replace ...................................... 70 Secondary Filter of

Fuel System - Replace .............. 71 Hoses and Clamps
- Inspect/Replace ............... 74 Radiator -
Clean ................................................ .. 75

For every 1000 hours of service

Engine Valve Clearance - Inspect/Adjust ...................... 67

Every 2,000 hours of service

Post-cooler core - Inspect .............................. 52 Alternator -

Inspect ..... ......................................... 53 Engine Mounts -
Inspecting... ......................................... 64 Engine Start -
Inspect ................. ............................. 76 Turbocharger -
Inspect .............. ......................... 76 Water pump -
Inspect .................. ......................... 78
Machine Translated by Google
52 SEBU7833-03
Maintenance Section
Post-cooler core - Clean/Test

i02322260

Post-cooler core - Clean/Test

Personal injuries can result from air pressure.

Personal injuries can occur if the proper procedure

[Link] the core. Check the OEM information do not proceed. When using compressed air, use protection
for the correct procedure. facial and protective clothing.

2. Turn the core of the aftercooler upside down to The maximum air pressure at the nozzle must be less than 205 kPa (30
remove the debris. psi) for cleaning purposes.

8. Blow the core with compressed air. Direct the air in the direction
reverse of the normal flow.
Personal injuries can result from air pressure.
9. Inspect the core to ensure cleanliness.
Personal injuries can occur if the proper procedure is not followed. Pressure test on the core. If necessary, repair it.
essential.
do not be followed. When using compressed air, use protection
facial and protective clothing.
10. Install the core. Consult the OEM information for obtaining the
The maximum air pressure at the nozzle must be less than 205 kPa (30 correct procedure.
psi) for cleaning purposes.
11. After cleaning, start the engine and rev it to high speed.
idle rotations. This will help in the removal of debris.
Pressurized air is the preferred method for removal. and in the drying of the core. Turn off the motor. Use a lamp behind
loose debris. Direct the air in the opposite direction to the flow
from the core to inspect the core's cleanliness. Repeat the
from the fan. Hold the nozzle approximately 6 cleaning, if necessary.
0.25 mm away from the fins. Move slowly the
air inlet in a direction parallel to the pipes. This will remove
the debris that is between the tubes.
i02322295

Pressurized water can also be used for cleaning. Post-cooler core - Inspect
The maximum water pressure for cleaning purposes must
be less than 275 kPa (40 psi). Use pressurized water to
soften the mud. Clean the core on both sides.
Note: Adjust the cleaning frequency according to the effects of
operational environment.

NOTICE
Inspect the aftercooler for these items: damaged fins,
Do not use a high concentration of caustic cleaner to clean the
corrosion, dirt, grease, insects, leaves, oil and other debris. Clean
core. A high concentration of caustic cleaner can attack the
internal metals of the core and cause leaks. Use only the the aftercooler, if necessary.

recommended concentration of cleaner.

For air-air after coolers, use the same methods used for
clean radiators.

5. Perform backwashing of the core with a suitable cleaning product.

[Link] the core with steam to remove any residue.

Wash the fins of the post-cooler core. Personal injuries can result from air pressure.
Remove any other debris stuck.
Personal injuries can occur if the proper procedure is not followed.
do not be followed. When using compressed air, use protection
7. Wash the core with hot water and soap. Rinse well.
core with clean water. face and protective clothing.

The maximum air pressure at the nozzle must be less than 205 kPa (30
psi) for cleaning purposes.
Machine Translated by Google
SEBU7833-03 53
Maintenance Section
Alternator - Inspect

After the cleaning, start the engine and rev it up to high RPM. For applications that require multiple drive belts,
slow march. This will help in the removal of debris and in the drying of the replace the belts with corresponding sets. Replace only
core. Stop the engine. a belt of a corresponding set will make the new belt
Use a lamp behind the core to inspect the cleanliness of the core. load more cargo because the older belt is stretched.
Repeat the cleaning, if necessary. The additional load on the new belt can cause the new belt to break.

Inspect the fins for damage. Bent fins may be opened. If the belts are too loose, the vibration causes
with a comb. unnecessary wear on belts and pulleys. Loose belts can
slip enough to cause overheating.
Note: If parts of the aftercooler system are repaired.
if replaced, a leakage test is highly recommended. To accurately check the belt tension, a suitable gauge
it must be used.
Inspect these items for good condition: Soldering, supports
assembly, air lines, connections, clamps, and seals. Make
repairs, if necessary.

i02322311

Alternator - Inspect

Perkins recommends a scheduled inspection of the alternator.

Inspect the alternator for loose connections and fix it.
battery charging. Check the ammeter (if equipped) during
the operation of the engine to ensure the correct performance of the battery and/
or the correct performance of the electric system. Make repairs as needed. Illustration 26 g01003936
necessary.
Typical example

Burroughs Meter

Check if the alternator and the battery charger are functioning.

correctly. If the batteries are charged correctly, Fit the gauge (1) in the center of the longest free length and
check the tension. The correct tension is 535 N (120 lb). If the tension of
the reading of the ammeter should be very close to zero. All the
batteries should be kept charged. Batteries must be if the belt is below 250 N (56 lb), adjust the belt to 535 N (120 lb)
kept heated because temperature affects starting power. If lb).

If the battery is too cold, it will not start the engine. When the engine
it does not work for long periods of time or if the engine runs If double belts are installed, check and adjust the tension.
on both belts.
for short periods, the batteries may not charge completely. A
A battery with a low charge will freeze more easily than a battery.
with full load. Adjustment

i01929797

Alternator and fan belts -

Inspect/Adjust/Replace

Inspection
To maximize engine performance, inspect the belts.
regarding wear and cracks. Replace worn or damaged belts.

Illustration 27 g01003939

1. Loosen the alternator mounting bolt (2) and the bolt

(3).
Machine Translated by Google
54 SEBU7833-03
Maintenance Section
Battery - Replace

[Link] the alternator to increase or 5. Remove the used battery.

reduce the tension of the belt. Tighten the hinge screw
the alternator and the connection bolt to 22 N·m (16 lb ft).(1). 6. Install the new battery.

Substitution Note: Before connecting the cables, make sure that the switch
The engine start should be OFF.

Consult the Disassembly and Assembly Manual for the

7. Connect the starter motor cable to the POSITIVE terminal
installation procedure and the removal procedure of the
belt. + battery.

8. Connect the NEGATIVE cable "-" to the NEGATIVE terminal "-" of the

i02322315 battery.

Battery - Replace
i02747977

Battery electrolyte level -

Verify

The batteries emit flammable gases that can explode.

A spark can cause the ignition of combustible gases.
This can result in serious personal injury in the jury or death. When the engine doesn't work for long periods of time or
when the engine runs for short periods, the batteries may
do not fully recharge. Ensure a full charge
Ensure proper ventilation for the batteries that are in to help prevent the battery from freezing. If the batteries
a cabinet. Follow the proper procedures to help are correctly loaded, the ammeter reading
to avoid electrical arcs and/or sparks near the batteries. No must be very close to zero when the engine is in operation.
smoke during battery maintenance.

All lead-acid batteries contain sulfuric acid.

that can burn the skin and clothing. Always use a sunscreen.
facial and protective clothing when working with batteries or nearby
The battery cables or the batteries should not be removed.
with the battery cover in place. The battery cover must
to be removed before any maintenance.
1. Remove the fuel caps. Maintain the level of
electrolyte at the 'FULL' mark in the battery.
Remove the battery cables or the batteries with the cover on.
place can cause battery explosion, resulting in If water needs to be added, use distilled water. If
personal injuries. if distilled water is not available, use clean water with
low mineral content. Do not use artificially softened water.

1. Put the engine in the OFF position. Remove all loads.

electrical.
2. Check the condition of the electrolyte with a tester
appropriate battery.
2. Turn off all battery chargers. Disconnect all of them.
battery chargers. 3. Install the lids.

The NEGATIVE cable "-" connects the NEGATIVE terminal "-" of the
[Link] the batteries clean.
battery to the NEGATIVE terminal "-" of the starter motor.
Disconnect the NEGATIVE '-' terminal cable from the battery.
Clean the battery box with one of the following solutions
of cleaning:
4. The POSITIVE wire “+” connects to the POSITIVE terminal “+” of
Use a solution of 0.1 kg (0.2 lb) of bicarbonate
battery to the POSITIVE terminal "+" of the starter motor. sodium and 1 L (1 qt) of clean water.
Disconnect the cable from the POSITIVE terminal '+' of the battery.

Use a solution of ammonium hydroxide.

Note: Always recycle a battery. Never dispose of one. Rinse the battery case thoroughly with clean water.
battery. Dispose of used batteries in an installation of
appropriate recycling.
Machine Translated by Google
SEBU7833-03 55
Maintenance Section
Battery or Battery Cable - Disconnect

i02323088 i02203590

Battery or battery cable - Cooling System Refrigerant

disconnect (Heavy Commercial Service)
Change

NOTICE
The battery cables or batteries should not be removed. Care must be taken to ensure that fluids are contained.
with the battery cover placed. The battery cover must be
during the execution of inspection, maintenance, testing, adjustment, and repair
removed before any maintenance.
of the product. Be prepared to collect the fluid with containers
suitable before opening any compartment or disassembling
any component that contains fluids.
Remove the battery cables or the batteries with the cover on
the place can cause battery explosion, resulting in injuries
personal.
Dispose of all fluids in accordance with regulations and mandates.
places.
1. Turn the ignition key to the OFF position. Turn the switch to
ignition (if equipped) to the OFF position and remove the key
TO PERCEIVE
and all electric charges.
Keep all parts free from contaminants.

[Link] the negative terminal from the battery. Make sure that
the cable cannot make contact with the terminal. When Pollutants can cause rapid wear and shorten life
useful of the components.
four 12-volt batteries are involved, two connections
negatives must be disconnected.
Clean the cooling system and wash it before the break
3. Remove the positive connection. maintenance recommended if the following exist
conditions:
4. Clean all disconnected connections and terminals.
battery.
The engine frequently overheats.

5. Use fine sandpaper to clean the Foam formation is observed.

cable terminals and clamps. Clean the items until they
surfaces remain clear or shiny. DO NOT remove the The oil entered the cooling system and the
excessive material. The excessive removal of material the soda is contaminated.
can you make the clips not fit
correctly. Cover the clips and the terminals with a The fuel entered the cooling system and the liquid of
silicone lubricant or petroleum jelly. refrigeration is contaminated.

6. Secure the cable connections with adhesive tape to Note: When the cooling system is cleaned, only
help avoid accidental matches. clean water is necessary.

7. Proceed with the necessary repairs to the system. Note: Inspect the water pump and the regulator
water temperature after draining the cooling system.
8. To connect the battery, connect the This is a good opportunity to replace the water pump, the
positive connection before the negative connector. water temperature regulator and hoses, if necessary.

Ralo

Pressurized system: The hot refrigerant liquid can

cause severe burns. To open the supply cap
of the cooling system, turn off the engine and wait until
the components of the cooling system cool down. Loosen
slowly the pressure cap of the cooling system to relieve the pressure
of course.
Machine Translated by Google
56 SEBU7833-03
Maintenance Section
Cooling Liquid of the Cooling System (Heavy-Duty Commercial) - Change

1. Turn off the engine and let it cool down. [Link] off the engine and let it cool.
Slowly open the filling cap of the system Slowly unscrew the filling cap of the system.
cooling to relieve any pressure. Remove the lid of cooling to relieve any pressure. Remove the lid of
cooling system supply. cooling system supply. Open the tap of
drain or remove the engine drain plug. Open the valve
from the drainage or remove the radiator drain plug. Leave
let the water flow. Clean the cooling system with clean water.

Fill in

1. Close the drain tap or install the drain plug in the engine.
Close the drainage tap or install the drainage plug in the
radiator

NOTICE No
fill the cooling system with more than 5 L (1.3 US gal) per minute
to avoid air blockages.
Illustration 28 g01003928
Air blockages in the cooling system can result in engine damage.
2. Open the drain faucet or remove the drain plug (1) from the
engine. Open the drain valve or remove the drain plug
2. Fill the cooling system with Commercial
of the radiator.
Heavy Coolant Liquid. Add Supplemental Additive for
Soda to soda. For the correct amount, consult the
Let the soda drain.
Operation and Maintenance Manual, topic 'Recommendations of'
"Fluids" (Maintenance Section) for more information on the
NOTICE
cooling system specifications. Do not install the cap of
Dispose of the used engine coolant or recycle it. Various cooling system supply.
methods have been proposed to recover used refrigerant for reuse
in engine cooling systems. The distillation procedure
complete is the only acceptable method by Perkins to recover the 3. Start and operate the engine at low RPM. Increase the engine RPM.
soda.
for high rotation. Let the engine run at high rotation for a
minute to purge the air from the engine block cavities. Stop the
To obtain information on disposal and recycling of motor.
used refrigerant, consult the Perkins dealer or the Perkins distributor.
4. Check the coolant level. Keep the coolant level
within 13 mm (0.5 in.) below the bottom of the tube for
filling. Keep the level of the refrigerant liquid in the bottle of
Blush
expansion (if equipped) at the correct level.

1. Wash the cooling system with clean water to remove any

5. Clean the coolant system fill cap.
detritus.
Inspect the gasket on the fill cap of the system.
cooling. If the gasket that is on the filling cap of the system
2. Close the drain valve or install the drain plug on the engine.
if the cooling system is damaged, dispose of the filler cap
Close the drainage tap or install the drainage plug in
from the old cooling system and install a new cap of
radiator.
filling of the cooling system. If the gasket on the cover
if the cooling system is not damaged, use a pump of
NOTICE No adequate pressurization to test the pressure of the system lid
fill the cooling system with more than 5 L (1.3 US gal) per minute cooling. The correct pressure for the supply cap of
to avoid air blockages. cooling system is stamped on the face of the lid
cooling system supply. If the cap of
Air blockages in the cooling system can result in engine damage. the cooling system supply does not retain the correct pressure,
install a new coolant system cap.

3. Fill the cooling system with clean water. Install the cap.
6. Turn on the engine. Inspect the cooling system for
filling of the cooling system.
leaks and the correct operating temperature.

4. Turn it on and let the engine run at low speed until it

temperature reaches 49 to 66 °C (120 to 150 °F).
Machine Translated by Google
SEBU7833-03 57
Maintenance Section
Cooling System Coolant (ELC) - Change

i02203595 1. Turn off the engine and let it cool.

Slowly open the filler cap of the system of
Cooling System Coolant (ELC) cooling to relieve any pressure. Remove the lid of

Move supply of the cooling system.

NOTICE
Care must be taken to ensure that fluids are contained
during the execution of inspection, maintenance, testing, adjustment and repair
of the product. Be prepared to collect the fluid with containers
suitable before opening any compartment or disassembling
any component that contains fluids.

Dispose of all fluids in accordance with regulations and mandates.

places.

Illustration 29 g01003928
PERCEIVE
Keep all parts free from contaminants. Typical example

Contaminants can cause rapid wear and shorten the lifespan. 2. Open the drainage tap or remove the drainage plug (1)
useful of the components. Turn on the motor. Open the drainage tap or remove the plug.
radiator drainage.

Clean the cooling system and flush it before the break. Let the soda drain.
maintenance recommended if the following exist
conditions NOTICE
Dispose of used engine coolant or recycle it.
The engine frequently overheats.
Several methods have been proposed to recover used refrigerant.
for reuse in engine cooling systems. The
Foam formation is observed.
total distillation procedure is the only acceptable method by the
Perkins to recover the refrigerant.
The oil entered the cooling system and the
the soda is contaminated.
To obtain information about disposal and recycling of
The fuel entered the cooling system and the liquid of used refrigerant, consult the Perkins dealer or distributor
refrigeration is contaminated. Perkins.

Note: When the cooling system is clean, only

clean water is needed when the ELC is drained and replaced.
Blush
1. Wash the cooling system with clean water to remove
any debris.
Note: Inspect the water pump and the regulator
water temperature after draining the cooling system.
2. Close the drain faucet or install the drain plug in the
This is a good opportunity to replace the water pump, the
motor. Close the drain tap or install the plug.
water temperature regulator and hoses, if necessary. drainage in the radiator.

NOTICE
Ralo Do not fill the cooling system with more than 5 L (1.3 US gal)
per minute to avoid air blockages.

Air blockages in the cooling system can result in engine damage.

Pressurized system: The hot refrigerant liquid can
cause severe burns. To open the supply cap
[Link] the cooling system with clean water. Install the cap.
of the cooling system, turn off the engine and wait until
cooling system filling.
the components of the cooling system cool down. Loosen
slowly the pressure cap of the cooling system to relieve the pressure
of course. 4. Turn on and let the engine run at low RPM until the
temperature reaches 49 to 66 °C (120 to 150 °F).
Machine Translated by Google
58 SEBU7833-03
Maintenance Section
Cooling System Coolant - Replacement

[Link] off the engine and let it cool. i01929799

Slowly unscrew the filler cap of the system
cooling to relieve any pressure. Remove the lid of Cooling System Coolant -
supply of the cooling system. Open the faucet of
drain or remove the engine drain plug. Open the tap of
Change
drain or remove the radiator drain plug. Let the
water run off. Clean the cooling system with clean water.

Fill

[Link] the drainage tap or install the drainage plug in the engine.
Close the drainage tap or install the drainage plug in the
radiator.

NOTICE No
fill the cooling system with more than 5 L (1.3 US gal) per minute
to prevent air blockages.

Air blockages in the cooling system can result in engine damage.

Illustration 30 g01003928

2. Fill the cooling system with Coolant Drain valve

Extended Life (ELC). Refer to the Operation Manual and

Maintenance, topic "Fluid Recommendations" (Section of NOTICE No
Maintenance) for more information on the specifications of drain the coolant while the engine is still hot and the
cooling system. Do not install the supply cap of system under pressure, as the hot and dangerous coolant liquid can
cooling system. be downloaded.

3. Start and operate the engine at low RPM. Increase the engine RPM.
for high rotation. Let the engine run at high rotation for a Note: The radiator may not have been provided by Perkins. The following is

minute to purge the air from the engine block cavities. Stop the engine. a general procedure for changing the refrigerant. Consult the
OEM information to obtain the correct procedure.

4. Check the coolant level. Maintain the coolant level.

within 13 mm (0.5 in.) below the bottom of the tube for 1. Make sure the vehicle is level with the ground.
filling. Keep the level of the refrigerant liquid in the bottle of
expansion (if equipped) at the correct level. [Link] the coolant system fill cap.

5. Clean the coolant system filler cap. [Link] the drain plug (1) from the side of the
Inspect the gasket that is on the filling cap of the system. cylinder block to drain the engine. Make sure that the hole for
drainage should not be blocked.
cooling. If the gasket that is on the fill cap of the system
If the cooling is damaged, discard the filling cap.
from the old cooling system and install a new cap of 4. Open the radiator drain valve or remove the plug
filling of the cooling system. If the gasket that is on the cover drainage at the bottom of the radiator to drain the radiator. If
the radiator does not have a drain valve or a plug
if the cooling system is not damaged, use a pump of
adequate pressurization to test the pressure of the system cap for drainage, disconnect the hose at the bottom of the radiator.
cooling. The correct pressure for the supply cap of
the cooling system is stamped on the face of the lid
supply of the cooling system. If the cap of 5. Wash the cooling system with clean water.
the cooling system supply does not maintain the correct pressure,
install a new coolant system cap. 6. Install the drain plugs and close the radiator drain valve.
Install the radiator hose if the radiator hose was
6. Start the engine. Inspect the cooling system for removed previously.
leaks and the correct operating temperature.
7. Fill the system with an approved antifreeze mixture.
the maximum flow rate is 1 L (0.2200 Imp gal) per minute for

fill the system. Install the filling cap.

8. Turn on the engine and check for refrigerant leaks.

Machine Translated by Google
SEBU7833-03 59
Maintenance Section
Coolant system extender (ELC) - Add

i02335364 1. Observe the level of the refrigerant liquid in the recovery tank.
refrigerant. Keep the refrigerant liquid level at the 'COLD' mark.
Cooling System Refrigerant
"FULL" in the recovery tank of the refrigerant fluid.
Extensor (ELC) - Add

Pressurized system: The hot refrigerant liquid can cause

The Extended Life Coolant (ELC) from Perkins does not require the
severe burns. To open the supply cap of the system
frequent addition of Supplemental Cooling Additives (SCA) that are
cooling, turn off the engine and wait for the components to
associated with conventional soft drinks. The Extender only needs to be added
cooling system cool down. Slowly loosen the pressure cap
once.
cooling system to relieve pressure
sure.
Check the cooling system only when the engine is off
It is cold.

2. Slowly loosen the filler cap to release any

[Link] loosen the fuel supply cap of the system pressure. Remove the filler cap.
cooling to relieve pressure. Remove the supply cap
Pour the correct mixture of soda into the tank.
of the cooling system.
Consult the Operation and Maintenance Manual, 'Capabilities and

It may be necessary to drain enough coolant from the cooling system. "Restocking Recommendations" to obtain information about
to add the extender. the correct mixture and the type of soda. Consult the Manual of
Operation and Maintenance, 'Capabilities and Recommendations of

3. Add the Extender according to the system capacity requirements Refueling for the cooling system capacity. No
of cooling your engine. Consult this Operating Manual and fill the refrigerant recovery tank above the mark
Maintenance, 'Refueling Capabilities' in the Section of COLD FULL
Maintenance to determine the capacity of the cooling system of
your engine.
Consult the information in this Operation and Maintenance Manual,
Fluid recommendations for the Perkins ELC Extender.

4. Clean the filler cap of the cooling system and inspect it.
gasket. If the gasket is damaged, discard the old filler cap
and install a new filler cap. If the seal is not damaged,
use an appropriate pressurization pump to test the pressure of the
filling cap. The correct pressure is stamped on the face of the cap
of filling. If the filling cap does not retain the correct pressure,
install a new fill cap.

Illustration 31 g00103639
i02335378
4. Clean the fuel cap and the receptacle. Reinstall the
Coolant liquid level of the cooling system
filler cap and inspect the cooling system for leaks.
Verify
Note: The coolant will expand as it heats up.
heating during normal engine operation. The additional volume will be
forced into the refrigerant recovery tank during the
engine operation. When the engine is stopped and cold, the coolant will return
Engines with Refrigerant Recovery to the engine.
Tank
Engines without coolant
Note: The cooling system may not have been provided by
Perkins. The following procedure is for typical cooling systems. recovery tank
Check the OEM information for the correct procedures.
Check the coolant level when the engine is off and
cold.

Check the coolant level when the engine is off and

cold.
Machine Translated by Google
60 SEBU7833-03
Maintenance Section
Equipment activated - Check

Lubrication

Other maintenance recommendations

Perform any maintenance for the activated equipment that

be recommended by the OEM.

i01930350

Clean Motor

Illustration 32 g00285520

Cooling system filling cap Personal injury or death can result from high voltage.

Moisture can create pathways for electrical conductivity.

Pressurized system: The hot refrigerant liquid can

to cause severe burns. To open the supply cap
Make sure the electrical system is OFF.
of the cooling system, turn off the engine and wait until
Block the start controls and mark the controls "NO"
the cooling system components cool down. Loosen OPERATE.
slowly the pressure cap of the cooling system to relieve the pressure
of course.
NOTICE
Grease and oil accumulated in an engine represent a risk of
1. Slowly remove the coolant system filler cap.
fire. Keep the engine clean. Remove debris and spills
to relieve the pressure.
of fluid whenever a significant amount accumulates in the
motor.
Keep the soda level within 13 mm (0.5 in) from the
bottom part of the filling tube. If the engine is
equipped with a level gauge, maintain the liquid level of NOTICE
cooling at the correct level on the level display.
Stop protecting some engine components from washing
it may void the engine warranty.
3. Clean the coolant system filler cap and
Let the engine cool for an hour before washing it.
inspect the joint. If the joint is damaged, discard it.
old filler cap and install a new cap of
filling. If the gasket is not damaged, use a pump
adequate depressurization to test the pressure of the lid It is recommended to periodically clean the engine.
inflation. The correct pressure is stamped on the face of the lid. The steam cleaning of the engine will remove accumulated oil and grease.
of filling. If the filling cap does not retain the pressure A clean engine offers the following benefits:
correct, install a new fill cap.

4. Inspect the cooling system for leaks. Easy detection of fluid leaks

Maximum heat transfer characteristics

i00174798

Equipment activated - Check Ease of maintenance

Note: Care should be taken to avoid having the components

electricals are damaged by excess water during the
engine cleaning.
Consult the OEM specifications for more information
High-pressure washers and steam cleaners should not be
on the following maintenance recommendations for the
directed to any electrical connector or to the junction of cables in
equipment activated:
rear part of the connectors. Avoid electrical components, such as the
alternator and the starter motor.
Inspection
Protect the fluid injection pump to wash the engine.
Adjustment
Machine Translated by Google
SEBU7833-03 61
Maintenance Section
Engine Air Filter Element (Dual Element) - Clean/Replace

i01915869 Double element air filters

Air purifier element of the engine The dual element air filter contains a filter element of
(Double element) - Clear/Replace the primary and a secondary air filter element.
The primary air purifying element can be used up to six.
sometimes if it is properly cleaned and inspected. The element
the primary air purifier filter should be replaced at least once
once a year. This replacement must be made
NOTICE
regardless of the number of cleanings.
Never start the engine without an air filter element installed.
Never start the engine with a damaged air filter element.
Do not use pleated air filter elements, joints, or seals.
The secondary air purifier element cannot be repaired.
damaged. The entry of dirt into the engine causes wear. or washable. Check the OEM information for details
premature and damage to the engine components. The elements of
Instructions to replace the secondary air filter element.
air purifiers help to prevent airborne debris
When the engine is operating in dusty environments
enter the air intake.
If dirty, the air filter elements may need replacement.
more frequent.
NOTICE
Never perform maintenance on the air filter element with the engine running.
functioning, as this will allow dirt to enter the engine.

Maintenance of the air filter elements

Note: The air filter system may not have been provided.
by Perkins. The following procedure is for a system of
typical air filter. Check OEM information for obtaining
the correct procedure.

If the air filter element gets clogged, the air can split the
material of the air filter element.
Unfiltered air will drastically accelerate internal wear. Illustration 33
g00736431
of the motor. Consult the OEM information for the
Coverage
correct air filter elements for your application.
(2) Primary element of the air purifier
Secondary air purifier element
• Check the pre-filter (if equipped) and the dust reservoir Air intake

daily regarding the accumulation of dirt and debris.

Remove any dirt and debris as necessary. 1. Remove the cover. Remove the primary element of
air purifier.
The operating conditions (dust, dirt, and debris) can
require more frequent maintenance of the filter element The element of the secondary air purifier must be
from the removed and discarded every three cleanings of the element
primary air purifier.
The air filter element must be replaced at least once
once a year. This replacement must be carried out Note: Refer to "Cleaning the primary elements of the purifier"
regardless of the number of cleanings. of ar

Replace the dirty air filter elements with filter elements Cover the air intake with adhesive tape to prevent dirt.
of air clean. Before installation, the elements of the air filter forums.
must be carefully checked for tears and/or
holes in the filter material. Inspect the gasket or seal of the 4. Clean the inside of the cap and the body of the air filter with a cloth.
air filter element regarding damage. clean and dry.
Maintain a supply of suitable air filter elements
for substitution purposes. 5. Remove the tape from the air intake. Install the
secondary air purification element. Install an element
primary air purifier that is new or clean.

6. Install the air filter cover.

7. Redefine the air filter maintenance indicator.

Machine Translated by Google
62 SEBU7833-03
Maintenance Section
Engine Air Filter Element (Dual Element) - Clean/Replace

Cleaning the primary air purifier

elements
PERCEIVE
Follow the following guidelines when trying to clean the filter element:

Do not hit or tap the filter element to remove dust.

Do not wash the filter element.

Use low-pressure compressed air to remove dust from the

filter element. The air pressure should not exceed 207 kPa (30
Illustration 34 g00281692
Direct the airflow up and down on the folds.
start from the interior of the filtering element. Be very careful to
avoid damage to the vocal folds. Note: When the primary elements of the purifier
when cleaning the sides, always start from the clean side (inside) to
force the dirt particles to the dirty side (outside).
Do not use air filters with pleats, joints, or damaged seals.
dirt entering the engine will cause damage to its components
motor. Direct the hose so that the air flows into the element.
length of the filter to help prevent damage to the folds
Do not point the air jet directly at the element.
Check the OEM information to determine the number of
primary of the air purifier. The dirt can be forced even further
times that the primary filtering element can be cleaned. When the
in the folds.
primary element of the air purifier for clean, check if there is
features or traits in the filter material.
Note: Consult 'Inspection of primary elements of
The primary element of the air purifier must be replaced with air purifier.
less than once a year. This replacement must be made
regardless of the number of cleanings.
Vacuum cleaner
NOTICE
Vacuum cleaning is a good method for cleaning the elements.
Do not clean the air filter elements by hitting or banging. This primary air purifier components that require daily cleaning
can damage the seals. Do not use elements with folds, joints due to a dry and dusty environment.
or damaged seals. Damaged elements will allow the Cleaning with compressed air is recommended before vacuuming.
dirt passage. Damage to the engine may occur. Vacuum cleaning will not remove carbon and oil deposits.

Note: Consult 'Inspection of primary elements of'

Visually inspect the primary elements of the purifier
air purifier
of the air before cleaning them. Inspect the air filter elements
regarding damage to the sealing, joints, and outer cover.
Discard all damaged air filter elements. Inspection of the primary air purifier
elements
There are two common methods used to clean the elements
primary air purifier components:

Pressurized air

Vacuum cleaning

Pressurized Air
The pressurized air can be used to clean the elements
primary air purifiers that have not been cleaned more than twice
times. The pressurized air will not remove carbon deposits.
the oil. Use dry and filtered air with a maximum pressure of 207 kPa (30
psi).

Illustration 35 g00281693
Machine Translated by Google
SEBU7833-03 63
Maintenance Section
Engine Air Filter Element (Simple Element) - Inspect/Replace

Inspect the primary air purifier element, clean and dry. Some engines are equipped with a differential gauge for the
Use a 60-watt blue light in a dark room or in a inlet air pressure. The differential gauge for pressure
similar installation. Place the blue light on the primary element of the inlet air shows the difference in pressure measured before the
air purifier. Turn the primary element of the air purifier. air filter element and the pressure measured after the element of
Inspect the primary element of the air purifier for air filter. As the air filter element becomes dirty, the
features and/or holes. Inspect the air purifier element pressure differential increases. If your engine is equipped
primary regarding the light that may appear through the material of with a different type of service indicator, follow the
filter. If necessary to confirm the result, compare the OEM recommendations for maintaining the indicator
primary element of the air purifier with a new element air filter service.
primary air purifier with the same part number.

Do not use a primary air purifying element that has The service indicator can be mounted on the filter element.
features and/or holes in the filter material. Do not use an element from the air or in a remote location.

primary air purifier with pleats, joints or seals

damaged. Discard the primary elements of the air purifier
damaged.

i02152042

Engine air purifier

Element (Unique Element) -
Inspect/Replace

Consult the Operation and Maintenance Manual, 'Service Inspector'

of the Engine Air Filter. Illustration 36 g00103777

Typical service indicator

NOTICE
Never start the engine without an air filter element installed. Observe the service indicator. The air filter element
Never start the engine with a damaged air filter element. Do not it must be cleaned or replaced when one of the occurs
use air filter elements with pleats, joints or seals following conditions:
damaged. The entry of dirt into the engine causes premature wear
and damage to the engine components. The elements of the purifier of
help prevent airborne debris from entering the The yellow diaphragm enters the red zone.
air intake.
The red piston locks in the visible position.

NOTICE
Never perform maintenance on the air filter element with the engine running.
Test the service indicator
functioning, as this will allow dirt to enter the engine.
Service indicators are important tools.

A wide variety of air filters can be installed for use • Check the ease of rebooting. The service indicator
with this engine. Refer to the OEM information for the must restart in less than three touches.
correct procedure for replacing the air filter.
• Check the movement of the yellow core when the engine is
accelerated to the engine's nominal speed.
i01909507
The yellow core should lock approximately in the greatest vacuum.

Engine air purification service hit.

Indicator - Inspect If the service indicator does not restart easily, or if the core
yellow should not stop in the maximum vacuum, the service indicator must
to be replaced. If the new service indicator does not restart, the
service indicator opening may be restricted.
Some engines may be equipped with an indicator of
different maintenance.
The service indicator may need to be replaced with
frequency in very dusty environments.
Machine Translated by Google
64 SEBU7833-03
Maintenance Section
Motor Grounding - Inspect/Clean

i01941505

Motor Grounding - Inspect/Clean

Inspect the electrical harness for good connections.

A Perkins uses the starter motor to ground the engine. Check the
connection to the starter motor every oil change. Wires and strips of
Grounding must be combined with the motor ground.
All groundings must be firm and free of corrosion.

Clean the starter motor ground pin and the terminals

with a clean cloth. Illustration 37 g01165836

Min
If the connections are corroded, clean them.
connections with a solution of baking soda and water. PERCEIVE
Perform this maintenance with the engine stopped.

Keep the grounding pin and strap clean and coated

with appropriate grease or vaseline. Note: make sure the engine is leveled or in the
normal operating position to obtain a real level indication.

i02323089

Engine Mounts - Inspect Note: After turning off the engine, wait ten minutes to
allow the engine oil to drain into the sump before checking the
oil level.

Note: The engine supports may not have been provided. 1. Keep the oil level between the 'ADD' mark (Y) and the mark
by Perkins. Check the OEM information for more "FULL" (X) on the engine oil dipstick.
Do not fill the oil sump above the "FULL" mark (X).
information about the engine mounts and the correct torque of the
screw.

Inspect the engine mounts for deterioration and for NOTICE

correct torque of the screws. The engine vibration can be Operate the engine when the oil level is above the mark
caused by the following conditions: "CHEIO" can cause the crankshaft to dive into the oil.
Air bubbles created by the immersion of the crankshaft in oil reduce
Incorrect assembly of the engine the lubricating characteristics of the oil and can result in loss
of power.
Deterioration of the engine mounts

Loose motor mounts [Link] the oil fill cap and add oil if necessary.
Clean the oil filler cap. Install the oil filler cap.

Any engine support that shows deterioration must be

replaced. Refer to the OEM information for the
i02202699
recommended torques.
Engine oil sample - Obtain
i02335785

Engine oil level - check

The condition of the engine oil can be checked in
regular intervals as part of a maintenance program
preventive. Perkins includes a sampling valve
oil as an option. The oil sampling valve (if
equipped) is included to regularly collect samples of the oil
Hot oil and hot components can cause injuries
engine lubricant. The oil sampling valve is
personal. Do not allow hot oil or hot components positioned at the head of the oil filter or the valve of
come into contact with the skin.
oil sampling is positioned in the cylinder block.
Machine Translated by Google
SEBU7833-03 65
Maintenance Section
Engine Oil and Filter - Change

Perkins recommends the use of a sampling valve for i01929323

obtain oil samples. The quality and consistency of the samples
are better when a sampling valve is used. The Engine Oil and Filter - Change
the sampling valve location allows the oil that
is flowing under pressure to be obtained during normal operation of the
motor.

Obtain the Sample and the Analysis

Hot oil and hot components can cause injuries
personal. Do not allow hot oil or hot components
make contact with the skin.

Hot oil and hot components can cause injuries

personal. Do not allow hot oil or hot components Do not drain the oil with the engine cold. As the oil cools down, the
come into contact with the skin. suspended waste particles settle at the bottom of the
cart. The residual particles are not removed with the drainage
of cold oil. Drain the oil pan with the engine off. Drain the oil pan
To help achieve the most accurate analysis, record the following with hot oil. This drainage method allows for the
information before collecting an oil sample: particles of debris that are suspended in the oil
drained properly.

The sample date

The non-compliance with this recommended procedure will result in
Engine model that the residual particles be recirculated by the system of
engine lubrication with new oil.
Engine number

Service hours on the engine Drain the engine oil

The number of hours accumulated since
the last oil change

The amount of oil added since the last oil change

Make sure that the container for the sample is clean and dry.
Make sure that the container for the sample is
clearly labeled.

To ensure that the sample is representative of the oil in

Drain, obtain a sample of hot, well-mixed oil.

Illustration 38 g01003623
To avoid contamination of the oil samples, the tools
and the inputs used for obtaining the samples of Oil drain
oils must be clean.
After the engine operates at normal operating temperature,
The sample can be checked for the following: the quality turn off the engine. Use one of the following methods to
of oil, the existence of any refrigerant in the oil, the existence drain the oil from the engine sump:
of ferrous metal particles in the oil and the existence of
non-ferrous metal particles in the oil. If the engine is equipped with a drain valve, turn the
drain valve button counterclockwise to drain
the oil. After draining the oil, turn the valve button of
drainage clockwise to close the drainage valve.

If the engine is not equipped with a drain valve,

remove the oil drain plug (1) to allow for
oil drainage. If the engine is equipped with a sump
Remove the lower oil drain plugs from both.
the ends of the crankcase.
Machine Translated by Google
66 SEBU7833-03
Maintenance Section
Engine Oil and Filter - Change

After draining the oil, the oil drain plugs must

to be clean and installed. If necessary, replace the sealing ring in
Oh the drainage plug.

Some types of sumps have oil drain plugs on both

the sides of the oil pan, due to the shape of the oil pan. This type of oil pan
requires that the engine oil be drained from both plugs.

Replace the threaded oil filter

NOTICE The
Perkins oil filters are manufactured according to specifications
from Perkins. The use of an oil filter not recommended by Perkins.
Illustration 39
g01003628
it can result in serious damage to the engine bearings, crankshaft,
etc., as a result of larger residual particles of unfiltered oil Filter head
(3) sealing ring in O
entering the engine lubrication system. Use only oil filters
recommended by Perkins.
3. Clean the sealing surface of the oil filter head (2).
Make sure that the union (not shown) at the head of the filter
the oil should be firm.
[Link] the oil filter with a suitable tool.
4. Apply clean motor oil to the O-ring (3) on the filter.
Note: The following actions can be performed as part of oil.
preventive maintenance program.
NOTICE No
2. Open the oil filter with an appropriate tool. Separate the
fill the oil filters with oil before installing them.
check and inspect the oil filter for metal debris. This oil would not be filtered and could be contaminated. The oil
An excessive amount of metal debris in the oil filter
contaminated can cause accelerated wear of the components of
may indicate premature wear or an impending failure.
motor.

Use a magnet to differentiate between ferrous and non-ferrous metals. 5. Install the oil filter. Tighten the oil filter by hand.
non-ferrous metals found in the oil filter element. Metals according to the instructions indicated on the oil filter. Do not tighten
Ferrous materials can indicate wear on steel and cast iron parts besides the oil filter.
to do motor.

Replace the element with the oil

Non-ferrous metals can indicate wear in the parts of
aluminum, brass or bronze of the engine. The parts that can be
Filter
affected items include the following: main bearings,
rod bearings, turbocharger bearings, and cylinder heads.

Due to normal wear and tear, it is not uncommon

find small amounts of debris in the oil filter.

Illustration 40
g01003662

Drain plug
square hole
Filter bowl

1. Place a suitable container under the oil filter.

Remove the drain plug (1) and the oil filter seal.
Machine Translated by Google
SEBU7833-03 67
Maintenance Section
Engine Valve Clearance - Inspect/Adjust

2. Locate a suitable key in the square hole (2) to remove

the filter cup (3). NOTICE
To avoid damage to the crankshaft bearing, start the engine with the
3. Remove the cup from the filter (3) and take out the filter cup element. fuel OFF. This will fill the oil filters before starting
Clean the filter cup. the engine. Do not start the engine for more than 30 seconds.

2. Turn on the engine and let it run in 'LOW'

"IDLE" for two minutes. Execute this procedure to ensure
that the lubrication system has oil and that the filters
the oil be filled. Check the oil filter for
oil leaks.

3. Turn off the engine and let the oil drain back into the sump for
at least ten minutes.

Illustration 41 g01003675

O-ring seal

(5) Element
Filter head

Illustration 42 g00998024
4. Install a new sealing ring (4) in the filter cup and lubricate it.
(Y) Mark 'ADD'. (X) Mark 'FULL'.
seal ring with clean motor oil. Install the element of the
filter (5) in the filter cup.
[Link] the oil level gauge to check the oil level.
Keep the oil level between the 'ADD' and 'FULL' marks on the
5. Install the filter cup on the oil filter head (6).
engine oil dipstick.
Tighten the filter cup with the following torque of 25 N·m (18
lb ft).
i02171102
[Link] a new seal on the drain plug (1) and
Install the drain plug in the oil filter. Tighten the plug. Engine Valve Clearance
drainage with the following torque of 12 N·m (8 lb ft).
Inspect/Adjust
Note: Some engines may have an oil filter installed.
horizontally. This oil filter has a drain plug
located at the head of the oil filter.
This maintenance is recommended by Perkins as part of a
lubrication and preventive maintenance schedule to help
Fill the engine oil sump to provide the maximum engine lifespan.

[Link] the oil supply cap. Refer to the Operation

the Maintenance Manual for more information about NOTICE
lubricant specifications. Fill the oil pan with the amount Only qualified service personnel should perform this maintenance.
adequate oil. Please refer to the Operation and Maintenance Manual
Consult the service manual or your authorized Perkins dealer
to obtain more information about the capabilities of
or your Perkins distributor to obtain the complete procedure for
refueling. adjustment of the valve clearance.

NOTICE If The operation of Perkins engines with incorrect valve clearance can
equipped with an auxiliary oil filter system or a system of reduce the efficiency of the engine and also reduce the lifespan of the
remote oil filter, follow the recommendations of the OEM or manufacturer engine components.
of the filter. Insufficient or excessive filling of the sump with oil
it can cause damage to the engine.
Machine Translated by Google
68 SEBU7833-03
Maintenance Section
Fuel Injector - Test/Change

Make sure the engine cannot be turned on while this

maintenance is being carried out. To help prevent possible
injuries, do not use the starter motor to turn the steering wheel.

Hot engine components can cause burns.

Wait longer for the engine to cool down before measuring/adjusting the
valve clearance.

Make sure the engine is off before measuring the clearance.

valve. The clearance of the engine valves can be inspected
it should be adjusted when the engine temperature is hot or cold.

Consult Operation/Test and Adjustment of Systems, 'Valve Play'

"Motor - Inspect/Adjust" for more information.

i02198352

Fuel Injector - Test/Change

Illustration 43 g01110422

Typical fuel injectors

Fuel spilled or leaked on hot surfaces or
Electrical components can cause fire. The fuel injector (1) will need to be removed and the performance
the injector will need to be checked.

NOTICE No
Fuel injectors should not be cleaned, as cleaning with
allow dirt to enter the fuel system. Clean incorrect tools can damage the nozzle. The injectors of
completely the area around a component of the system of fuel should only be replaced if a failure occurs
fuel that will be disconnected. Install a proper cap
in our fuel injectors. Some of the problems that may indicate
about the disconnected component of the fuel system. the need for new fuel injectors is listed below:

NOTICE If
The engine won't start or the engine is having difficulty.
there is suspicion of a fuel injector operating outside of the to start.
normal parameters, it must be removed by a qualified technician.
The suspected fuel injector must be taken to an agent.
There is not enough energy
authorized for inspection.

The engine fails or operates irregularly.

The fuel injector (1) in illustration 43 does not have a return.
fuel. The fuel injector (2) has a fuel return. High fuel consumption

Black exhaust smoke

The engine knocks or there is vibration in the

motor.

Excessive engine temperature

Machine Translated by Google
SEBU7833-03 69
Maintenance Section
Fuel System - Prime

Removal and Installation of Use the following procedure to remove air from the fuel system:

Fuel injectors
1. Make sure that all low-pressure fuel connections and
high-pressure fuel lines are properly installed.

Work carefully around a running engine. Turn the ignition key to the RUN position. Leave the ignition key
The engine parts that are hot or in motion can cause in the RUN position for three minutes. If a purge screw
injuries. If the manual is installed, the purge screw must be loosened
during the fuel system draining.

Make sure to wear eye protection at all times during the

test. When the fuel injectors are tested, the
test fluids travel through the holes at the tip of the nozzle under high pressure.
Under this amount of pressure, the test fluid can puncture the skin.
and cause serious injuries to the operator.

Always keep the tip of the fuel injector pointed towards

far from the operator and into the fuel collector and extension.

NOTICE If
if your skin comes into contact with fuel under high pressure, seek
immediate medical assistance. Illustration 44 g01003929

Typical example

Operates the engine at fast idle to identify the injector of

3. Start the engine with the throttle lever in the position
defective fuel. Loosen and tighten the coupling nut individually.
CLOSED until the engine starts.
of the high-pressure tube for each fuel injector. Do not loosen
the union nut more than half a turn. There will be little effect on the rotation of
Note: If necessary, loosen the cover nuts (1) on the lines of
engine when the union nut of the faulty fuel injector is
frouxada. Please refer to the Disassembly and Assembly Manual for more information.
fuel injection at the connection with the fuel injector until
that the fuel be evident. Stop starting the engine.
information. Consult your authorized Perkins dealer or your
Tighten the cap nuts (1) with a torque of 30 N·m (22 lb ft).
Perkins dealer for assistance.

4. Turn on the engine and let it run idling for a

minute.

i02890360
NOTICE No
Fuel System - Prime start the engine continuously for more than 30 seconds. Let the engine
Cool down for two minutes before starting the engine again.

If air enters the fuel system, the air must be purged from the
fuel system before the engine can be started. The air 5. Move the throttle lever from the low rotation position to the position
you can access the fuel system when the occur of high rotation three times. The cycle time for the lever of
following events: accelerator is from one second to six seconds for a complete cycle.

The fuel tank is empty or the fuel tank has been

partially drained. Note: to purge air from the fuel injection pump
in Perkins engines with fixed throttle, the engine must operate with
The low-pressure fuel lines are disconnected. total charge for thirty seconds.
The load should then be reduced until the engine is at high speed.
There is a leak in the low-pressure fuel system. This must be repeated three times.
This will help remove the trapped air from the fuel injection pump.
The fuel filter is replaced.

A new injection pump is installed. [Link] for leaks in the fuel system.
Machine Translated by Google
70 SEBU7833-03
Maintenance Section
Primary Fuel System Filter Element (Water Separator) - Replace

i02206563 2. Place a suitable container under the water separator.

Clean the outside part of the water separator.
Primary Fuel System Filter
(Water Separator) Element -
[Link] the drain (5). Let the fluid flow into the container.
Replace

4. Open the drain (5) only with manual pressure.

5. Secure the element (2) and remove the screw (1).

Remove the element and the glass bowl (3) from the base. Discard it.
ancient element.
Fuel leaked or spilled on hot surfaces or
Electrical components can cause fire. To help prevent
6. Clean the glass bowl (4). Clean the bottom lid
possible injuries, turn off the starter switch when changing the
(6).
fuel filters or water separating elements.
Clean up fuel spills immediately.
7. Install the new sealing ring in O. Install the bottom cover on the new one.
element. Install the set on the base.
NOTICE No
allow dirt to enter the fuel system. Clean
completely the area around a system component of 8. Install the screw (1) and tighten it until
fuel that will be disconnected. Install a suitable cap Torque of 8 N·m (6 lb-ft).
about the disconnected component of the fuel system.
9. Remove the container and dispose of the fuel
with safety.

10. Open the fuel supply valve.

11. Write down the fuel system. Consult the Operation Manual.
Maintenance, 'Fuel System - Strain' to obtain
more information.

i02211066

Primary Fuel System

Water Filter/Separator - Drain

Fuel leaked or spilled on hot surfaces or

Electrical components can cause fire. To help prevent it
possible injuries, turn off the starter switch when changing the
fuel filters or the water separator elements.
Clean up the fuel spills immediately.

NOTICE
Water separator is not a filter. The water separator separates the water.
Illustration 45 g01118416 of fuel. The engine should never run with the separator of
water more than half full. Damage to the engine may occur.
Screw
Element
Glass bowl
Sensor connection
Drain NOTICE
lower Tampa water separator is under suction during normal operation of
motor. Make sure the drain valve is well tightened
1. Place the fuel supply valve (if equipped) in the OFF position to help prevent air from entering the fuel system.
position.
Machine Translated by Google
SEBU7833-03 71
Maintenance Section
Secondary Fuel System Filter - Replace

NOTICE No
allow dirt to enter the fuel system. Clean completely
the area around a component of the fuel system that will be
disconnected. Install a proper cover over the component
disconnected from the fuel system.

element filter
Turn the fuel line valves (if equipped) to the position
Turn OFF before performing this maintenance.
Place a tray under the fuel filter to collect any
fuel that may spill. Clean up any immediately.
spilled fuel.

Illustration 46 g01118416

Screw
(2) Element
Glass bowl
Sensor connection
Drain
lower Tampa

1. Place a suitable container under the water

separator.
Illustration 47 g01010637

2. Open the drain (5). Let the fluid flow into the container. Drain
Filter bowl

1. Close the fuel line valves (if equipped).

3. When the clean fuel flows out of the water separator, shut off the
drain (5). Squeeze the drain only with manual pressure. Discard
2. Clean the external part of the fuel filter assembly. Open the drain.
the fluid drained correctly.
fuel (1) and drain the fuel into a suitable container.

i02469473

Secondary Fuel System Filter

Replace

Fuel spilled or leaked on hot surfaces or

Electrical components can cause fire. To help prevent
possible injuries, turn off the starter switch when changing the
fuel filters or water separating elements.
Clean up the fuel spills immediately.
Machine Translated by Google
72 SEBU7833-03
Maintenance Section
Secondary Fuel System Filter - Replace

Illustration 48 g01010595

O-ring seal in O

Element
Filter head

3. Remove the glass from the filter (2) of the filter head
(5). Press the element (4). Turn the element counter-clockwise.
time to release the cup element from the filter and remove it Illustration 49 g01121396

cup element. Discard the used element. Filter head

Rotary filter
Drain

4. Remove the sealing ring (3) from the filter cup and
clean the filter cup. Check if the threads of the filter cup are not 1. Clean the outer part of the fuel filter assembly. Open the

are damaged. fuel drain (3) and drain the fuel into a container
adequate.

[Link] a new seal ring in O (3) in the filter cup (2).

2. Use an appropriate tool to remove the threaded filter (2)

6. Locate a new filter element (4) in the filter cup. from the filter head (1).
Press the element and rotate it clockwise to
lock the element in the filter glass. 3. Make sure that the fuel drain (3) in the new filter
the threaded part is closed.

7. Install the filter cup (4) on top of the filter head (5).

8. Squeeze the filter cup with your hand until the filter cup fits in.
contact with the filter head. Rotate the filter cup by 90
degrees.

Note: Do not use a tool to squeeze the filter cup.

9. Open the fuel line valves (if equipped).

Rotary filter
Turn the fuel line valves (if equipped) to the
turn OFF before performing this maintenance.
Place a tray under the fuel filter to collect any
fuel that may spill. Clean up any immediately.
spilled fuel.
Machine Translated by Google
SEBU7833-03 73
Maintenance Section
Fuel Tank Water and Sediments - Drain

Water can be introduced into the fuel tank when the tank is
fuel is being refueled.

Condensation occurs during the heating and cooling of the fuel.

Condensation occurs when the fuel passes through the system of
fuel and returns to the fuel tank. This causes the water
it accumulates in the fuel tanks. Drain the fuel tank
Regularly obtaining fuel from reliable sources can help eliminate
the water in the fuel.

Drain the water and the sediment

The fuel tanks must have some provision to drain the water.
to drain the sediments from the bottom of the fuel tanks.

Open the drain valve at the bottom of the fuel tank to drain.
the water and the sediments. Close the drainage valve.

Illustration 50 g01121723
Check the fuel daily. Wait five minutes after the
fuel tank having been filled before draining the water and the
4. Lubricate the sealing ring (4) with clean fuel oil. sediments from the fuel tank.

[Link] the threaded filter (2) on top of the filter head (1). Fill the fuel tank after operating the engine to expel
the humid air. This will help to avoid condensation. Do not fill the tank up to
the top. The fuel expands as the fuel heats up.
6. Tighten the threaded filter manually until the seal ring fits in. The tank may overflow.
in contact with the filter head. Turn the rotating filter 90 degrees.

Some fuel tanks use supply tubes that allow

7. Write down the fuel system. Refer to the Operating Manual and that the water and sediments settle below the end of the
Maintenance, 'Fuel System - Rinse'. fuel supply pipe. Some fuel tanks
we use supply lines that take the fuel directly
from the bottom of the tank. If the engine is equipped with this system, the
i02335436
Regular maintenance of the fuel system filter is important.
Fuel Tank Water and Sediments
Ralo Fuel storage tanks

Drain the water and sediments from the storage tank

fuel in the following intervals:

NOTICE Should-
Weekly
take care to ensure that the fluids are contained during the
execution of inspection, maintenance, testing, adjustment, and repair of the product. Be
Service intervals
prepared to collect the fluid with appropriate containers before opening
any compartment or dismantle any component that contains
Tank refueling
fluids.

This will help prevent water or sediments from being pumped from the tank.
for storage to the engine's fuel tank.
Discard all fluids according to local regulations and mandates.

If a bulk storage tank has been refilled or moved

Fuel tank recently, give enough time for the sediment to settle before
to fill the fuel tank of the engine. The internal deflectors in
bulk storage tanks will also help retain the
The quality of the fuel is essential for performance and longevity
sediments. The filtration of the fuel that is pumped from the tank of
engine. Water in the fuel can cause excessive wear in the system
Storage helps ensure fuel quality.
of fuel.
When possible, water separators should be used.
Machine Translated by Google
74 SEBU7833-03
Maintenance Section
Hoses and clamps - inspect/replace

i02813964 Early expansion and contraction of the hose

Hoses and Clamps - • Anticipated expansion and contraction of

Inspect/Replace accessories

Replace the hoses and the clamps

Inspect all hoses for leaks caused by the Consult the OEM information for more details on how to
following conditions: remove and replace the fuel hoses (if equipped).

Cracks The cooling system and the hoses for the cooling system
usually are not provided by Perkins. The following text describes
Softness
a typical method for refrigerant hose replacement. Consult the
OEM information to obtain more information about the system of
Loose straps refrigeration and the hoses for the refrigeration system.

Replace the cracked or soft hoses. Tighten any clamps.

loose.

WARNING No
Pressurized system: The hot refrigerant liquid can cause
Good or hit the high-pressure lines. Do not snap lines, tubes or
severe burns. To open the fuel supply cap of the system
crooked or damaged hoses. Repair any lines, tubes, and hoses
cooling, turn off the engine and wait until the components of
of fuel and oil that are loose or damaged. Leaks can cause
cooling system cool down. Slowly loosen the pressure cap
fires. Inspect all lines, pipes, and hoses carefully.
of the cooling system to relieve pressure.
Tighten all connections to the recommended torque. Do not bind any.
another item in the high pressure lines.

1. Turn off the engine. Let the engine cool down.

Check the following conditions:

Slowly unscrew the radiator cap of the cooling system.
to relieve any pressure. Remove the fuel filler cap from
End connections that are damaged or leaking
cooling system.

External covering that is worn or cut Note: Drain the refrigerant into a clean and suitable container.
soda can be reused.
Exposed wire that is used for reinforcement

3. Drain the coolant from the cooling system for a

External coverage that is inflating locally
level that is below the hose being replaced.

Flexible part of the hose that is bent or crumpled

4. Remove the clamps from the hose.

Built-in shielding in the outer cover [Link] the old hose.

A constant torque hose clamp can be used in place of

6. Replace the old hose with a new one.
of any standard hose clamp. Make sure that the clamp
the constant torque hose should be the same size as the clamp
7. Install the hose clamps with a torque wrench.
standard.

Note: To obtain the correct soda, consult this Manual of

Due to extreme temperature changes, the hose will harden. Operation and Maintenance, 'Fluid Recommendations'.
hardening of the hoses will cause the clamps of the
hoses may come loose. This can result in leaks. A clamp of
8. Refill the cooling system. Consult the OEM.
constant torque hose will help avoid hose clamps
information to obtain more information about the refueling of the
loose.
cooling system.

Each installation application may be different. The differences depend

9. Clean the coolant system cap. Inspect the
of the following factors:
seals of the coolant system fill cap. Replace
the cap of the cooling system may have leaks if the seals are damaged.
Type of hose
Install the coolant system filler cap.

Type of mounting material

10. Start the engine. Inspect the cooling system for
leaks.
Machine Translated by Google
SEBU7833-03 75
Maintenance Section
Radiator - Clean

i02335774 Inspect the fins for damage. Bent fins can be

opened with a "comb". Inspect these items for good quality.
Radiator - Clean conditions: Welds, mounting supports, air lines,
connections, clamps, and seals. Make repairs if necessary.

The radiator is usually not provided by Perkins. The text to i02335775

follow describes a typical radiator cleaning procedure.
Consult the OEM information for more details. Serious Service Application -
about radiator cleaning. Verify
Note: Adjust the cleaning frequency according to the effects of
operational environment.
Severe service is the application of a motor that exceeds the standards.
Inspect the radiator for these items: Damaged fins, current publications for that engine. Perkins maintains standards
corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean for the following engine parameters:
the radiator, if necessary.

• Performance as power range, speed range and

fuel consumption

Personal injuries can result from air pressure.

Fuel quality

Personal injuries can occur if the proper procedure is not followed.

Operational altitude
Do not follow. When using compressed air, use protection.
facial and protective clothing.
Maintenance intervals

The maximum air pressure at the nozzle must be less than 205 kPa (30
Selection and maintenance of oil
psi) for cleaning purposes.

Type of refrigerant and maintenance

Pressurized air is the preferred method for removing loose debris.
Direct the air in the opposite direction to the airflow of the fan. Environmental qualities
Hold the mouthpiece approximately 6 mm (0.25 in) away
the radiator fins. Slowly move the air nozzle in a Installation
direction parallel to the radiator tube set. This will remove the
debris that is between the tubes. The fluid temperature in the engine

Check the engine specifications or consult the Perkins dealer or

Pressurized water can also be used for cleaning. the Perkins distributor to determine if the engine is operating
The maximum water pressure for cleaning purposes should be less than within the defined parameters.
275 kPa (40 psi). Use pressurized water to soften the mud.
Clean the core on both sides.
The severe service operation can accelerate the wear of the
components. Motors that operate under severe conditions can
Use a degreaser and steam for the removal of oil and grease. need more frequent maintenance intervals for
Clean both sides of the core. Wash the core with detergent and to ensure maximum reliability and maintenance of the total lifespan.
hot water. Rinse the core well with clean water.

Due to individual applications, it is not possible to identify.

If the radiator is blocked internally, consult the Manual all the factors that can contribute to an operation of
from the OEM to obtain information about the system flushing severe service. Consult the Perkins dealer or distributor
cooling. Perkins for obtaining the exclusive maintenance needed for the
motor
After cleaning the radiator, start the engine. Let the engine
run on low idle for three to five minutes. Accelerate The operational environment, operational procedures
the engine for high rotation. This will help in the removal of debris and in incorrect and improper maintenance procedures can be
core drying. Slowly reduce the motor speed factors that contribute to a severe service application.
for low idle and then turn off the engine. Use a
lamp behind the core to inspect the cleanliness of the core.

Repeat the cleaning if necessary.

Machine Translated by Google
76 SEBU7833-03
Maintenance Section
Starter Motor - Inspect

Environmental Factors Check if the starter motor is working correctly. Check

check the electrical connections and clean the electrical connections. Consult the

Ambient temperatures - The engine can be exposed to Operating manual, testing and adjustment of the systems, 'Starting system'
prolonged operation in extremely cold environments or electric - test" to obtain more information about the procedure
hot. The components of the valve can be damaged. of verification and specifications or consult the Perkins dealer or the
due to carbon build-up if the engine is turned on and off with Perkins dealer for assistance.
frequency at very low temperatures. The intake air
extremely hot reduces engine performance.

i02184788

Air quality – The engine may be exposed to prolonged operation.

Turbocharger - Inspect
in a dirty or dusty environment, unless the equipment
be cleaned regularly. Mud, dirt, and dust can accumulate (Be equipped)
the components.
Maintenance can be very difficult. The accumulation may contain products.
corrosive chemicals.
Regular visual inspection of the turbocharger is recommended.
Accumulation – Compounds, elements, chemicals Any vapors from the crankcase are filtered through the system of
Corrosives and salt can damage some components. air intake. Therefore, the byproducts of the oil and combustion
can accumulate on the compressor housing of the turbocharger.
Altitude - Problems may arise when the engine is operated at Over time, this accumulation can contribute to a loss of power.
altitudes higher than the desired configurations for this application. due to motor, increase of black smoke and overall loss of efficiency of
Necessary adjustments must be made. motor.

If the turbocharger fails during the engine operation, it can

Incorrect Operational Procedures damage to the compressor wheel of the turbocharger and/or
to the engine. Damage to the wheel of the turbocharger compressor
Extended operation at low rotation
can cause additional damage to the pistons, valves, and the cylinder head
of the cylinder.
Frequent hot shutdowns

• Operating with excessive loads

NOTICE

• Operating at excessive speeds Failures in the turbocharger bearings can cause

large amounts of oil enter the air intake and exhaust systems.
Operating outside the intended application The loss of engine lubricant can result in serious damage to the engine.

Incorrect maintenance procedures A small oil leak in a turbocharger in operation

prolonged low rotation should not cause problems, as long as
Extending maintenance intervals there has not been a failure in the turbocharger bearing.

Failure in the use of fuel, lubricants and

coolant/antifreeze
When a failure in the turbocharger bearing is accompanied by
due to a significant loss of engine performance (smoke from
exhaust or increase in engine speed without load), do not continue
i02177969
the operation of the engine until the turbocharger is replaced.
Starter Motor - Inspect
A visual inspection of the turbocharger can minimize downtime.
unplanned inactivity. A visual inspection of the turbocharger
it can also reduce the chance of potential damage to other parts of
Perkins recommends a scheduled inspection of the starter motor.
motor.
If the starter motor fails, the engine may not start.
emergency situation.
Removal and installation

Note: The supplied turbochargers cannot be

repaired.
Machine Translated by Google
SEBU7833-03 77
Maintenance Section
General inspection

For options related to removal, installation, and replacement, consult The guards must be in the correct place. Fix the guards.
the Perkins dealer or the Perkins distributor. Refer to the Manual of damaged or replace the missing protections.
Disassembly and Assembly, "Turbocharger - Remove and
Turbo compressor - Install for more information. Clean all caps and plugs before starting the engine.
maintenance to reduce the chance of system contamination.

inspecting
NOTICE For
any type of leakage (coolant, lubricant or
NOTICE TO
fuel), clean the fluid. If a leak is observed, locate the source and
the casing of the turbocharger compressor should not be removed from the
fix the leak. If there is suspicion of a leak, check the levels
turbocompressor for cleaning. of fluid more frequently than recommended until the leak
be found or fixed, or until the suspicion of leakage is
The actuator joint is connected to the compressor housing. If the proven as unjustified.
actuator articulation for moved or disturbed, the motor may not comply
the emissions legislation.
NOTICE
Grease and/or oil accumulated in an engine represent a fire hazard.
Remove the accumulated grease and oil. Refer to this Operation Manual.
1. Remove the exhaust pipe from the turbocharger and remove the
In Maintenance, 'Engine - Cleaning' to obtain more information.
air intake pipe for the turbocharger. Inspect
visually inspect the piping for the presence of oil. Clean the interior
two tubes to prevent dirt from entering during reassembly.
Make sure that the cooling system hoses are
well secured and that the hoses of the cooling system are
tightened. Check for leaks. Check the condition of all
2. Check for the presence of oil. If there is an oil leak in the part of the tubes.
Behind the compressor wheel, there is a possibility of failure in the seal.
of the turbocharger oil. Inspect the water pump for coolant leaks.

The presence of oil may be the result of prolonged operation of the Note: The water pump seal is lubricated by the liquid
motor at low rotation. The presence of oil can also be of the cooling system. It is normal for a
resulting from a blockage in the intake air line (filters of small leak as the engine cools and the parts contract.
clogged), which makes the turbocharger drool.

Excessive leakage of refrigerant may indicate the need for

3. Inspect the turbine outlet housing hole for replace the seal of the water pump. For the removal of the pump
corrosion. water and the installation of the water pump and/or sealing, consult the Manual
Disassembly and Assembly, 'Water Pump - Remove and Install'
4. Air intake duct or tube and exhaust outlet for more information or consult the Perkins dealer or the
tube for the turbocharger housing. Perkins distributor.

i02177973
Inspect the lubrication system for leaks in the seal.
General inspection front of the crankshaft, in the rear crankshaft seal, in the
oil pan, in the oil filters and in the rocker cover.

Inspect the fuel system for leaks. Look for loose components.
clamps and/or fuel line clamps.
Inspect the engine for leaks
and loose connections Inspect the air intake system piping and the elbows.
as for cracks and loose clamps. Make sure that the
A general inspection should take only a few minutes. When the hoses and tubes should not be in contact with others
time is spent to perform these checks, expensive repairs and hoses, tubes, electrical harnesses, etc.
accidents can be avoided.
Inspect the alternator belts and any belts of
To maximize the engine's lifespan, conduct a thorough inspection of activation of accessories regarding cracks, breaks or other damages.
engine compartment before starting the engine. Look for items like
oil or coolant leaks, loose screws, worn belts,
loose connections and accumulation of garbage. Make repairs as needed:
Machine Translated by Google
78 SEBU7833-03
Maintenance Section
Water pump - Inspect

The belts for multi-grooved pulleys need to be replaced.

as combined sets. If only one belt is replaced, the
the belt will support more load than the belts that were not replaced.
The oldest belts are stretched. The additional load on the new one.
the belt can cause the belt to break.

Drain the water and sediment from the fuel

tank daily to ensure that only clean fuel
enter the fuel system.

Inspect the wiring and wire harnesses for connections

loose and worn or frayed threads.

Inspect the grounding strip for a good connection and

in good condition.

Disconnect any battery chargers that are not

protected against starter motor current drain. Check
the state and the level of the electrolyte in the batteries, unless the engine
be equipped with a maintenance-free battery.

Check the state of the meters. Replace all meters.

that are cracked. Replace any meter that cannot be
to be calibrated.

i01907756

Water pump - Inspect

A faulty water pump can cause serious problems

of engine overheating that can result in the following
conditions:

Cracks in the cylinder head

An apprehension of the piston

Other potential damage to the engine

Note: The water pump seal is lubricated by

coolant of the cooling system. It is normal that
a small leak occurs as the engine cools and the parts
they contract.

Inspect the water pump visually for leaks.

Replace the water pump seal or the water pump if
there is excessive refrigerant leakage. Please consult the Manual
of Dismantling and Assembly, "Water Pump - Removal and
"Installation" for the disassembly and assembly procedure.
Machine Translated by Google
SEBU7833-03 79
Warranty Section
Warranty Information

Warranty Section

Warranty information
i01903596

Emission Guarantee
Information

This engine can be certified to meet the standards

of exhaust emissions and gas emission standards
prescribed by law at the time of manufacture, and
this engine may be covered by a Warranty of
Emissions. Consult your authorized Perkins dealer or
your authorized Perkins distributor to determine if your
the engine is certified for emissions and if your engine is
subject to an Emissions Guarantee.
Machine Translated by Google
80 SEBU7833-03
Index section

Index

A E

After starting the engine .............................. 30 After Electrical system................................................ .... 11 Practices of
Stopping the Engine............................. 32 Core of the Aftercooler - Grounding ...................................... 12 Stop of
Clean/Test ...................... 52 Heat exchanger core - Emergency .............................. 32 Certification of Emissions
Inspect........ ........................... 52 Alternator - Movie .............................. 20 Tag for engines
Inspect .................. ............................. 53 Alternator belts compatible........ ................. 20 Label for engines that
and of the fan - Inspect/Adjust/ comply with the emissions
Replace MSHA ..................... ......................................... 22
Adjustment............................................ .............. 53 Label for motors that do not comply with the
Inspection ............................... ......................... 53 emissions ....................................... ................ 22 Information
Substitution.................................. 54 Emission Guarantee .............. 79 Engine -
Clear................................................ ..... 60 Filter Element of
To the Engine (Double Element) - Clear/
B Replace ....................... ...................... 61 Cleaning the Elements
Air Purifier Basics ...... 62 Performing Maintenance on
Battery - Replace.............................................. .... 54 Level of Air Purifier Elements ........ ........... 61
Battery Electrolyte - Check ........................ 54 Battery or Cable Engine air filter element (single element) - Inspect/
from the Battery - Disconnect ....... ............ 55 Before starting the Replace.............................. ............. 63 Maintenance indicator
motor ....................... .. 10, 28 Prevention of of the engine air filter - Inspect...... 63 Test the Indicator of
Burns ............................... 7 maintenance............... .............. 63 Description of
Batteries 8 Liquid motor .............................. .................. 16 Cooling and Lubrication
soda 8 Motor
Oils................................ ................ 8 18 Engine Specifications ............................. 16 Engine Ground
- Inspect/Clean... ......................... 64 Identification of
Motor ....................... Elevation of 19
C Motor 24 Motor Mounts
Inspect........ ............................. 64 Oil and engine filter -
Operation in cold weather.............................. 33 Tips for operation Change .............. .............. 65 Drain the engine oil .................. ..............
in cold weather. ......................... 33 Leaving the Engine Running 65 Fill the engine oil sump .............................. .... 67 Replace
Lenta ..................... ...................... 34 Recommendations for the the oil filter element.............. 66 Replace the oil filter
coolant heating .......... 34 Recommendations Screwed .............. ............. 66 Engine oil level -
for the coolant ...... ............. 33 Viscosity of Verify .............................. ........ 64 Engine Oil Sample -
engine lubricant oil ............... 33 Start in time Get ........................... 64 Get the Sample and the
cold .......... ................................ 29 Coolant of the Analysis.............. 65 Engine Operation............................ .........................
Cooling System - Replace ........... ............. 58 Fluid 31 Engine start................ ......................... 11, 28 Stop of
Cooling of the Cooling System (Commercial Heavy-Duty) motor .............. ................................ 11, 32 Storage of
- Exchange ....................... ......................................... 55 motor 24 System of
Drainage 55 Cooling...... ......................................... 25 System of
Filling ....................................... ............................. 56 Exhaustion... ......................................... 25 Items
Wash .............. ......................................... 56 System of General . ................................................ 26 System of
Coolant (ELC) - Change.............. 57 Induction ....................................... 25 System of
Drene 57 Lubrication
Fill in .............. ................................................ .......... 58 - Inspect/Adjust.............. 67 Heating of
Download ...................................... ......................... 57 Extender
Motor 31
coolant fluid of the cooling system (ELC) -
Add..... 59 Cooling liquid level of the system
cooling - Check ........... 59 Engines with Tank of
Soda Recovery... 59 Engines Without Tank of
Recuperação de Refrigerante...... .. 59 Prevenção de esmagamento e prevenção de corte ........ 10
F

D Fire Prevention and Explosion Prevention .............. 8 Fire Extinguisher

of Fire .............................. ...................... 9 Lines, Pipes and
Activated equipment - Check.............................. 60 Hoses ...................... ................ 9
Machine Translated by Google
SEBU7833-03 81
Index Section

Fluid Recommendations.............................. 38 Specifications of M

Cooling System.... ...................... 45 Maintenance of
Cooling System ELC ........................ 47 Engine Maintenance Interval Schedule ........... 51 Section of
Oil ................................................. ......... 39 Specifications of Maintenance............................. 37 Illustrations of the view of
Fuel.............................. ..... 42 General Information about model.................. 13 1103 Model Views
Lubricants ........................ 38 Motor............... ........... 15 1104 Views of the Model of
Preface .......... ................................................ ..... 4 Warning from the Motor........................... ... 13 Views of
California Proposition 65 ........................ 4 Information of model ....................................... ........... 13 Assembly and
Literature 4 Dismantling.............................. .... 10
Maintenance interval
maintenance........ ................................ 4
Operation ................ ......................................... 4 O
Review... ................................................ ......... 4
Safety Operation section .................................................. .. 24
and the Effect of Cold Weather .............. ... 35 Conservation Practices of
Fuel.................. 31 Fuel Injector - Test/
Replace .. ................................ 68 Removal and Installation of the Injectors P
Fuel... 69 Fuel-Related Components
a Cold Climate........ 36 Fuel Filters............................... .................... Product Identification Information .............. 19 Section of
36 Fuel Heaters Product Information .............. ................ 13
36 Fuel Tanks
36 Fuel System - First......
69 Primary Fuel System Filter (Water Separator) R

Element - Replace ....................................... 70 Primary Filter of Radiator - Clean .............................................. ..... 75 Numbers of
Fuel System/Water Separator - reference ........................... .... 19 Registration for
Drain ....................................... ......................... 70 Secondary Filter Reference ....................................... 19 Capacities of
Fuel System - Replace............... 71 Filter of recharge.............................................. ..... 37 System of
elements.............................................. ..... 71 Filter Cooling.............................. ..... 37 System of
threaded 72 tank Lubrication ....................................... ..... 37
Fuel Water and Sediments - Drain ............... 73 Drain the
Water and the Sediments. ...................... 73 Tanks of
Fuel Storage........................... ............... 73 S
Fuel Tank .................. ............................. 73
Security messages.............................................. ..... 5 (1)
Universal Warning ...................................... ... 5 (2)
G Ether............................................. .................... 5 Section of
Security ....................... .............................. 5 Number Plate of
Meters and Indicators .............................. 27 General Information Series ............... ............................. 19 Serious Service Application -
of Risk ...................................... 6 Containing spill of Check .............. ......... 75 Environmental Factors..............................
fluid ........... ......................... 7 Penetration of 76 Incorrect maintenance procedures...... 76 Procedures
fluid ............................. 7 Air Pressure and Incorrect operation......... .... 76 Engine Start -
Water.............. ....................... 7 Inspecting ....................................... 76 Turning on the
Motor............................................. .. 29 Starting with Cables
Starting Assistants ........................ 30 Disconnecting the
H Motor .......... ......................................... 32

Hoses and clamps - Inspect/Replace ........... 74 Replace

the hoses and the clamps ........... .74
T

EU
Index........................................................ 3 Turbo compressor -
Inspect (if equipped)............... 76
Important Security Information ...................................... 2 Inspection............. ......................................... 77 Removal and
installation ......................................... 76

Elevation and storage ....................................... .24

Machine Translated by Google
82 SEBU7833-03
Index section

EM

General Inspection ...................................... 77 Inspect the Engine in

search for Leaks and for Connections
Fracas ....................................... ..... 77 Information of
Warranty ....................................... ..... 79 Section of
Guarantee .......................... ......... 79 Water pump -
Inspect........................... ........ 78
Machine Translated by Google

Information about products and resellers

Note: For the location of the product identification plates, consult the "Product Identification Information" section in the Operation Manual.
Maintenance.

delivery_date

product information

Model:

Product identification number:

Engine serial number:

Transmission serial number:

serial_number_of_generator

Attachment serial numbers:

Attachment information:

Customer equipment number:

Dealer equipment number:

Dealer information

Name: Branch:

Address:

Dealer contact Phone number Hours

Sales:

Parts:

service
Machine Translated by Google

Printed in the United Kingdom

Copyright © 2008 Perkins Engines Company Limited
All rights reserved