M0068760-05 (en-us)

August 2019

Operation and
Maintenance
Manual
2806F-E18TA and 2806J-E18TA
Industrial Engines
JGK (Engine)
P84 (Engine)
PP8 (Engine)
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions correctly.
Incorrect operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. You must not use
this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of
the product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not
be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
M0068760-05 3
Table of Contents

Table of Contents Maintenance Section

Refill Capacities............................................... 61
Foreword ........................................................... 4
Maintenance Recommendations .................... 78
Safety Section
Maintenance Interval Schedule....................... 81
Safety Messages............................................... 6

Additional Messages ......................................... 7

Warranty Section

Warranty Information...................................... 111

General Hazard Information.............................. 7

Burn Prevention................................................11 Reference Information Section

Fire Prevention and Explosion Prevention...... 12 Reference Materials .......................................112

Crushing Prevention and Cutting Prevention.. 14 Index Section

Mounting and Dismounting ............................. 14 Index...............................................................115

Before Starting Engine .................................... 14

Engine Starting................................................ 15

Engine Stopping .............................................. 15

Electrical System............................................. 15

Engine Electronics........................................... 16

Product Information Section

Model Views .................................................... 17

Product Identification Information ................... 23

Operation Section

Lifting and Storage .......................................... 25

Features and Controls..................................... 31

Engine Diagnostics ......................................... 42

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

Engine Operation ............................................ 51

Engine Stopping .............................................. 55

Cold Weather Operation ................................. 57

4 M0068760-05
Foreword

Foreword Some photographs or illustrations in this manual

show details or attachments that may be different
from your engine. Guards and covers may have been
California Proposition 65 Warning removed for illustrative purposes. Continuing
improvement and advancement of product design
Diesel engine exhaust and some of its may have caused changes to your engine which are
not included in this manual. Whenever a question
constituents are known to the State of arises regarding your engine, or this manual, please
California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins
and other reproductive harm. distributor for the latest available information.

WARNING – This product can Safety

expose you to chemicals
including ethylene glycol, which This safety section lists basic safety precautions. In
is known to the State of California to addition, this section identifies hazardous, warning
cause birth defects or other reproductive situations. Read and understand the basic
precautions listed in the safety section before
harm. For more information go to: operating or performing lubrication, maintenance,
and repair on this product.
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands Operation
after handling to avoid incidental Operating techniques outlined in this manual are
ingestion. basic. The operating techniques assist with
developing the skills and techniques required to
WARNING – This product can operate the engine more efficiently and economically.
expose you to chemicals Skill and techniques develop as the operator gains
including lead and lead knowledge of the engine and the capabilities of the
compounds, which are known to the engine.
State of California to cause cancer, birth The operation section is a reference for operators.
defects, or other reproductive harm. For Photographs and illustrations guide the operator
more information go to: through procedures of inspecting, starting, operating,
and stopping the engine. This section also includes a
www.P65Warnings.ca.gov discussion of electronic diagnostic information.

Wash hands after handling components Maintenance

that may contain lead.
The maintenance section is a guide to engine care.
Literature Information The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
This manual contains safety, operation instructions, intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
lubrication, and maintenance information. This
manual should be stored in or near the engine area in Recommended service should be performed at the
a literature holder or literature storage area. Read, appropriate intervals as indicated in the Maintenance
study, and keep the manual with the literature and Interval Schedule. The actual operating environment
engine information. of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
English is the primary language for all Perkins freezing cold operating conditions, more frequent
publications. The English used facilitates translation lubrication, and maintenance than is specified in the
and consistency. Maintenance Interval Schedule may be necessary.
M0068760-05 5
Foreword

The maintenance schedule items are organized for a

preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.

Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. Perkins recommends that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
Perkins also recommends that a maintenance record
be maintained as part of the permanent record of the
engine.
Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
authorized Perkins distributor or dealer. Your Perkins
dealer or your Perkins distributor offers various
options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available.
Consult with your Perkins dealer or your Perkins
distributor for information regarding these options.
6 M0068760-05
Safety Section
Safety Messages

Safety Section Universal Warning (1)

i06599865

Safety Messages

There may be several specific safety messages on

your engine. The exact location and a description of
the safety messages are reviewed in this section.
Become familiar with all safety messages.
Ensure that all the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and
soap to clean the safety messages. Do not use
Illustration 2 g01370904
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The One safety message is on the left side of the valve
safety messages that are loosened could drop off the mechanism cover. One safety message is on the
engine. right side of the engine gear case.

Replace any safety message that is damaged or

missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety Do not operate or work on this equipment unless
message on the replacement part. Your Perkins you have read and understand the instructions
distributor can provide new safety messages. and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.

Sulfuric Acid Burn (2)

Illustration 1 g06040012
Illustration 3 g01382725
Typical example
(1) Universal warning label The safety message for sulfuric acid burn is on the
(2) Sulfuric Acid Burn label side of the exhaust cooler.
M0068760-05 7
Safety Section
Additional Messages

This notice should be located next to the battery

disconnect switch.
Sulfuric Acid Burn Hazard may cause serious
personal injury or death. NOTICE
Do not turn the battery power disconnect switch off
The exhaust gas cooler may contain a small until indicator lamp has turned off. If the switch is
amount of sulfuric acid. The use of fuel with sul- turned off when the light is illuminated then the DEF
fur levels greater than 15 ppm may increase the system will not purge and DEF could freeze and
amount of sulfuric acid formed. The sulfuric acid cause damage to the pump and lines.
may spill from the cooler during service of the en-
gine. The sulfuric acid will burn the eyes, skin
and clothing on contact. Always wear the appro- i07728677
priate personal protective equipment (PPE) that
is noted on a material safety data sheet (MSDS)
for sulfuric acid. Always follow the directions for General Hazard Information
first aid that are noted on a material safety data
sheet (MSDS) for sulfuric acid.

i07676530

Additional Messages

There are several specific messages on this engine.

The exact location of the messages and the
description of the information are reviewed in this
section. Become familiar with all messages.
Make sure that all the messages are legible. Clean
the messages or replace the messages if the
messages are not legible. Replace the illustrations if
the illustrations are not legible. When cleaning the Illustration 5 g00104545
messages, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean Attach a “Do Not Operate” warning tag or a similar
the messages. Solvents, gasoline, or harsh warning tag to the start switch or to the controls
chemicals could loosen the adhesive that secures the before the engine is serviced or before the engine is
messages. Loose adhesive will allow the messages repaired. Attach the warning tags to the engine and
to fall. to each operator control station. When appropriate,
Replace any message that is damaged, or missing. If disconnect the starting controls.
a message is attached to a part that is replaced, Do not allow unauthorized personnel on the engine,
install a message on the replacement part. or around the engine when the engine is being
Replacement labels may be obtained from Perkins serviced.
distributors.
• Tampering with the engine installation or
tampering with the OEM supplied wiring can be
dangerous. Personal injury, death and/or engine
damage could result.
• Vent the engine exhaust to the outside when the
engine is operated in an enclosed area.
• If the engine is not running, do not release the
secondary brake or the parking brake systems
unless the vehicle is blocked or unless the vehicle
is restrained.
• Wear a hard hat, protective glasses, and other
protective equipment, as required.
Illustration 4 g03422039
Purge notice message
8 M0068760-05
Safety Section
General Hazard Information

• When working around an engine, the engine must • Start the engine from the operators station (cab).
not be in operation. You may only be near a Never short across the starting motor terminals or
running engine to carry out maintenance the batteries. This action could bypass the engine
procedures that require the engine to be in neutral start system and/or the electrical system
operation. could be damaged.
• Do not wear loose clothing or jewelry that can Engine exhaust contains products of combustion
snag on controls or on other parts of the engine. which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
• Ensure that all protective guards and all covers area. If the engine is in an enclosed area, vent the
are secured in place on the engine. engine exhaust to the outside.

• Never put maintenance fluids into glass Cautiously remove the following parts. To help
containers. Glass containers can break. prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Use all cleaning solutions with care.
• Filler caps
• Report all necessary repairs.
• Grease fittings
Unless other instructions are provided, perform the
maintenance under the following conditions: • Pressure taps

• The engine is stopped. Ensure that the engine • Breathers

cannot be started.
• Drain plugs
• The protective locks or the controls are in the
applied position. Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
• Engage the secondary brakes or parking brakes. bolts or nuts that are at opposite ends of the cover
plate or the device. Before removing the last two
• Block the vehicle or restrain the vehicle before bolts or nuts, pry the cover loose to relieve any spring
maintenance or repairs are performed. pressure or other pressure.

• Disconnect the batteries when maintenance is

performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads to help prevent sparks. If equipped,
allow the diesel exhaust fluid to be purged before
disconnecting the battery.
• If equipped, disconnect the connectors for the unit
injectors that are on the valve cover base. This
action will help prevent personal injury from the
high voltage to the unit injectors. Do not come in
contact with the unit injector terminals while the
engine is operating.
• Do not attempt any repairs or any adjustments to Illustration 6 g00702020
the engine while the engine is operating.
• Wear a hard hat, protective glasses, and other
• Do not attempt any repairs that are not protective equipment, as required.
understood. Use the proper tools. Replace any
equipment that is damaged or repair the • Perkins recommend that you do not stand next to
equipment. an exposed running engine unless it is necessary
when carrying out daily checks or maintenance
• For initial start-up of a new engine or for starting procedures. The appropriate Personal Protective
an engine that has been serviced, make Equipment (PPE) must be worn when standing
provisions to stop the engine if an overspeed next to an exposed running engine.
occurs. The stopping of the engine may be
accomplished by shutting off the fuel supply and/ • Do not wear loose clothing or jewelry that can
or the air supply to the engine. Ensure that only snag on controls or on other parts of the engine.
the fuel supply line is shut off. Ensure that the fuel
return line is open. • Ensure that all protective guards and all covers
are secured in place on the engine.
M0068760-05 9
Safety Section
General Hazard Information

• Never put maintenance fluids into glass

containers. Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads to help prevent sparks. Illustration 7 g00687600

• Do not attempt any repairs that are not Always use a board or cardboard when you check for
understood. Use the proper tools. Replace any a leak. Leaking fluid that is under pressure can
equipment that is damaged or repair the penetrate body tissue. Fluid penetration can cause
equipment. serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
Pressurized Air and Water from a doctor that is familiar with this type of injury.
Pressurized air and/or water can cause debris and/or
hot water to be blown out. This action could result in Containing Fluid Spillage
personal injury.
Care must be taken to ensure that fluids are
When pressurized air and/or pressurized water is contained during performance of inspection,
used for cleaning, wear protective clothing, protective maintenance, testing, adjusting, and repair of the
shoes, and eye protection. Eye protection includes product. Be prepared to collect the fluid with suitable
goggles or a protective face shield. containers before opening any compartment or
disassembling any component containing fluids.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum Dispose of all fluids according to local regulations
water pressure for cleaning purposes must be below and mandates.
275 kPa (40 psi).
Static Electricity Hazard when
Fluid Penetration
Fueling with Ultra-low Sulfur Diesel
Pressure can be trapped in the hydraulic circuit long Fuel
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to The removal of sulfur and other compounds in ultra-
escape rapidly if the pressure is not relieved low sulfur diesel fuel (ULSD fuel) decreases the
correctly. conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
Do not remove any hydraulic components or parts treated the fuel with a static dissipating additive.
until pressure has been relieved or personal injury Many factors can reduce the effectiveness of the
may occur. Do not disassemble any hydraulic additive over time. Static charges can build up in
components or parts until pressure has been relieved ULSD fuel while the fuel is flowing through fuel
or personal injury may occur. Refer to the OEM delivery systems. Static electricity discharge when
information for any procedures that are required to combustible vapors are present could result in a fire
relieve the hydraulic pressure. or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.
10 M0068760-05
Safety Section
General Hazard Information

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.
Avoid static electricity risk when fueling. Ultra-
low sulfur diesel fuel (ULSD fuel) poses a greater • Use a wet method to clean up asbestos materials.
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death • A vacuum cleaner that is equipped with a high
or serious injury from fire or explosion. Consult efficiency particulate air filter (HEPA) can also be
with your fuel or fuel system supplier to ensure used.
the delivery system is in compliance with fueling
standards for proper grounding and bonding • Use exhaust ventilation on permanent machining
practices. jobs.
• Wear an approved respirator if there is no other
Inhalation way to control the dust.

• Comply with applicable rules and regulations for

the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air.

Dispose of Waste Properly

Illustration 8 g00702022

Exhaust
Use caution. Exhaust fumes can be hazardous to
health. If you operate the equipment in an enclosed
area, adequate ventilation is necessary.

Asbestos Information
Perkins equipment and replacement parts that are
shipped from Perkins engine company limited are
asbestos free. Perkins recommends the use of only
genuine Perkins replacement parts. Use the following
guidelines when you handle any replacement parts Illustration 9 g00706404
that contain asbestos or when you handle asbestos
debris. Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
Use caution. Avoid inhaling dust that might be disposed of according to local regulations.
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:

• Never use compressed air for cleaning.

M0068760-05 11
Safety Section
Burn Prevention

Always use leakproof containers when you drain Cooling system conditioner contains alkali. Alkali can
fluids. Do not pour waste onto the ground, down a cause personal injury. Do not allow alkali to contact
drain, or into any source of water. the skin, the eyes, or the mouth.

Diesel Exhaust Fluid Oils

Skin may be irritated following repeated or prolonged
exposure to mineral and synthetic base oils. Refer to
your suppliers Material Safety Data Sheets for
DEF is an aqueous solution of urea which can re- detailed information. Hot oil and lubricating
lease ammonia vapors. Always wear the appro- components can cause personal injury. Do not allow
priate Personal Protective Equipment (PPE) that hot oil to contact the skin. Appropriate personal
is noted on a material safety data sheet (MSDS) protective equipment should be used.
for Diesel Exhaust Fluid (DEF).

• Do not inhale ammonia vapor or mist Diesel Fuel

• Do not eat, drink, or smoke in presence of DEF Diesel may be irritating to the eyes, respiratory
system, and skin. Prolonged exposure to diesel may
• Avoid DEF contact with eyes, skin, and cause various skin conditions. Appropriate personal
clothing protective equipment should be used. Refer to
supplier Material safety Data sheets for detailed
• Wash thoroughly after handling DEF information.

Always follow the directions for first aid that are Batteries
noted on a material safety data sheet (MSDS) for
Diesel Exhaust Fluid (DEF). The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
DEF is not expected to produce significant adverse electrolyte to contact the skin or the eyes.
health effects when the recommended instructions
for use are followed. Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
• Draining DEF must be carried out in a well explode.
ventilated area.
Always wear protective glasses when you work with
• Do not allow the DEF to be spilled onto hot batteries. Wash hands after touching batteries. The
surfaces. use of gloves is recommended.

i06086863
Engine and Aftertreatment System
Burn Prevention Do not touch any part of an operating engine or
engine aftertreatment system. Allow the engine or the
engine aftertreatment system to cool before any
maintenance is performed on the engine or the
Coolant engine aftertreatment system. Relieve all pressure in
the appropriate system before any lines, fittings, or
When the engine is at operating temperature, the related items are disconnected.
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.
Check that the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
12 M0068760-05
Safety Section
Fire Prevention and Explosion Prevention

Aftertreatment System and Diesel Store fuels and lubricants in correctly marked
Exhaust Fluid containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
Diesel Exhaust Fluid (DEF) temperatures can reach containers. Do not smoke in areas that are used for
65° to 70°C (149.° to 126°F) during normal engine storing flammable materials.
operation. Stop the engine. Wait for 15 minutes in Do not expose the engine to any flame.
order to allow the DEF system to be purged and the
DEF to cool before service or repair is performed. Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line, a
i05945996 tube, or a seal failure. Exhaust shields must be
installed correctly.
Fire Prevention and Explosion Do not weld on lines or tanks that contain flammable
Prevention fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Ensure that all
electrical wires are correctly installed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
or sparking.
Illustration 10 g00704000

Ensure that the engine is stopped. Inspect all lines

All fuels, most lubricants, and some coolant mixtures and hoses for wear or for deterioration. Ensure that
are flammable. the hoses are correctly routed. The lines and hoses
Flammable fluids that are leaking or spilled onto hot must have adequate support and secure clamps.
surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property Oil filters and fuel filters must be installed correctly.
damage. The filter housings must be tightened to the correct
torque. Refer to the Disassembly and Assembly
After the emergency stop button is operated, ensure manual for more information.
that you allow 15 minutes, before the engine covers
are removed.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of
combustible gases, consult your Perkins dealer and/
or your Perkins distributor for additional information
about suitable protection devices.
Remove all flammable combustible materials or
conductive materials such as fuel, oil, and debris
from the engine. Do not allow any flammable
combustible materials or conductive materials to
accumulate on the engine.
M0068760-05 13
Safety Section
Fire Prevention and Explosion Prevention

Illustration 11 g00704059 Illustration 12 g00704135

Use caution when you are refueling an engine. Do Gases from a battery can explode. Keep any open
not smoke while you are refueling an engine. Do not flames or sparks away from the top of a battery. Do
refuel an engine near open flames or sparks. Always not smoke in battery charging areas.
stop the engine before refueling.
Never check the battery charge by placing a metal
Avoid static electricity risk when fueling. Ultra-low object across the terminal posts. Use a voltmeter or a
Sulfur Diesel fuel (ULSD fuel) poses a greater static hydrometer.
ignition hazard than earlier diesel formulations with a
higher sulfur content. Avoid death or serious injury Incorrect jumper cable connections can cause an
from fire or explosion. Consult your fuel or fuel explosion that can result in injury. Refer to the
system supplier to ensure that the delivery system is Operation Section of this manual for specific
in compliance with fueling standards for proper instructions.
grounding and bonding practices.
Do not charge a frozen battery. A frozen battery may
cause an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.

Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

Ether
Ether is flammable and poisonous.
Do not smoke while you are replacing an ether
cylinder or while you are using an ether spray.
14 M0068760-05
Safety Section
Crushing Prevention and Cutting Prevention

Do not store ether cylinders in living areas or in the i05768982

engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49° C Mounting and Dismounting
(120° F). Keep ether cylinders away from open
flames or sparks.
Do not climb on the engine or the engine
Lines, Tubes, and Hoses aftertreatment system. The engine and
aftertreatment system have not been designed with
Do not bend high-pressure lines. Do not strike high- mounting or dismounting locations.
pressure lines. Do not install any lines that are
damaged. Refer to the OEM for the location of foot and hand
holds for your specific application.
Leaks can cause fires. Consult your Perkins dealer or
your Perkins distributor for replacement parts. i04257031

Replace the parts if any of the following conditions

are present: Before Starting Engine
• End fittings are damaged or leaking.

• Outer coverings are chafed or cut. NOTICE

For initial start-up of a new or rebuilt engine, and for
• Wires are exposed. start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
• Outer coverings are ballooning. occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.
Engine exhaust contains products of combustion
Make sure that all clamps, guards, and heat shields which may be harmful to your health. Always
are installed correctly. During engine operation, start and operate the engine in a well ventilated
correct installation will help to prevent vibration, area and, if in an enclosed area, vent the exhaust
rubbing against other parts, and excessive heat. to the outside.
Inspect the engine for potential hazards.
i02143194

Do not start the engine or move any of the controls if

Crushing Prevention and there is a “DO NOT OPERATE” warning tag or similar
warning tag attached to the start switch or to the
Cutting Prevention controls.
Before starting the engine, ensure that no one is on,
Support the component correctly when work beneath underneath, or close to the engine. Ensure that the
the component is performed. area is free of personnel.

Unless other maintenance instructions are provided, If equipped, ensure that the lighting system for the
never attempt adjustments while the engine is engine is suitable for the conditions. Ensure that all
running. lights work properly, if equipped.

Stay clear of all rotating parts and of all moving parts. All protective guards and all protective covers must
Leave the guards in place until maintenance is be installed if the engine must be started in order to
performed. After the maintenance is performed, perform service procedures. To help prevent an
reinstall the guards. accident that is caused by parts in rotation, work
around the parts carefully.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects. Do not start an engine when the governor linkage is
disconnected.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes. Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
Chips or other debris may fly off objects when objects provided in order to help prevent personal injury. The
are struck. Before objects are struck, ensure that no circuits are also provided in order to help prevent
one will be injured by flying debris. engine damage.
M0068760-05 15
Safety Section
Engine Starting

i07828827 • Allow the engine to run for five minutes to cool.

Engine Starting • Stop the engine.

Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
Do not use aerosol types of starting aids such as has been corrected.
ether. Such use could result in an explosion and
personal injury. Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to the
engine and/or shutting off the air supply to the
Engine exhaust contains products of combustion engine.
which may be harmful to your health. Always
start and operate the engine in a well ventilated To stop an electronically controlled engine, cut the
area and, if in an enclosed area, vent the exhaust power to the engine.
to the outside.
i06088340
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
Electrical System
the warning tag before the engine is started.
All protective guards and all protective covers must Never disconnect any charging unit circuit or battery
be installed if the engine must be started to perform circuit cable from the battery when the charging unit
service procedures. To help prevent an accident that is operating. A spark can cause the combustible
is caused by parts in rotation, work around the parts gases that are produced by some batteries to ignite.
carefully.
To help prevent sparks from igniting combustible
Start the engine from the operator's compartment or gases that are produced by some batteries, the
from the engine start switch. negative “−” jump-start cable should be connected
last from the external power source to the negative
Always start the engine according to the procedure “−” terminal of the starting motor. If the starting motor
that is described in the Operation and Maintenance is not equipped with a negative “−” terminal, connect
Manual, “Engine Starting” topic in the Operation the jump-start cable to the engine block.
Section. Knowing the correct procedure will help to
prevent major damage to the engine components. Check the electrical wires daily for wires that are
Knowing the procedure will also help to prevent loose or frayed. Tighten all loose electrical wires
personal injury. before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
To ensure that the jacket water heater (if equipped) is the “Engine Starting” section of this Operation and
working correctly, check the water temperature Maintenance Manual for specific starting instructions.
gauge and/or the oil temperature gauge during the
heater operation.
Grounding Practices
Note: The engine may be equipped with a device for
cold starting. If the engine will be operated in very Proper grounding for the engine electrical system is
cold conditions, then an extra cold starting aid may necessary for optimum engine performance and
be required. Normally, the engine will be equipped reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
with the correct type of starting aid for your region of
electrical circuit paths.
operation.
Uncontrolled electrical circuit paths can result in
i07668288 damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Engine Stopping Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
• Remove the load in increments.

• Open the circuit breaker.

16 M0068760-05
Safety Section
Engine Electronics

To ensure that the engine and the engine electrical Note: Many of the engine control systems and
systems function properly, an engine-to-frame display modules that are available for Perkins
ground strap with a direct path to the battery must be Engines will work in unison with the Engine
used. This path may be provided by way of a starting Monitoring System. Together, the two controls will
motor ground, a starting motor ground to the frame, provide the engine monitoring function for the specific
or a direct engine ground to the frame. engine application. Refer to the Troubleshooting
Manual for more information.
All grounds should be tight and free of corrosion. The
engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.

i06091234

Engine Electronics

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.

This engine has a comprehensive, programmable

Engine Monitoring System. The Engine Control
Module (ECM) will monitor the engine operating
conditions. If any of the engine parameters extend
outside an allowable range, the ECM will initiate an
immediate action.
The following actions are available for engine
monitoring control: WARNING, DERATE and
SHUTDOWN. These engine monitoring modes can
limit engine speed and/or the engine power.
Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring
functions. The following parameters can be
monitored as a part of the Engine Monitoring System:

• Operating Altitude
• Engine Coolant Level
• Engine Coolant Temperature

• Engine Oil Pressure

• Engine Speed

• Fuel Temperature
• Intake Manifold Air Temperature

• System Voltage
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
M0068760-05 17
Product Information Section
Model Views

Product Information
Section

Model Views
i06609024

Model View Illustrations

The following model views show typical features of

the engine. Due to individual applications, your
engine may appear different from the illustrations.

Engine Views

Illustration 13 g06045642
Typical example
(1) Drive belt (6) NOx Reduction System (NRS) valve (11) Adaptor of oil drain
(2) Refrigerant compressor (7) Electronic control modules (12) Alternator
(3) Valve mechanism cover (8) Starting motor (13) Vibration damper
(4) Fuel pump (9) Air intake (14) Belt tensioner
(5) Breather outlet hose (10) Secondary fuel filters
18 M0068760-05
Product Information Section
Model View Illustrations

Illustration 14 g06045668
Typical example
(15) Turbocharger (20) Oil gauge (Dipstick) (25) Fuel priming pump and primary fuel
(16) Coolant outlet (21) Coolant intake filter
(17) Water temperature regulator housing (22) Oil filters (26) NRS cooler
(18) Oil filler cap (23) Oil sample valve
(19) Coolant pump (24) Oil cooler
M0068760-05 19
Product Information Section
Model View Illustrations

Aftertreatment System
The aftertreatment items are supplied loose by
Perkins.
Clean Emission Module

Illustration 15 g06044166
Typical example
(1) Clean Emission Model (CEM) (4) DEF Injector (7) Aftertreatment Regeneration Device
(2) Exhaust outlet (5) Diesel Particulate Filter (DPF). (ARD)
(3) Selective Catalytic Reduction (SCR) (6) CEM sensors and fuel system (8) Exhaust Inlet
20 M0068760-05
Product Information Section
Product Description

Pump Electronic Tank Unit (PETU) NOx Sensors and DEF Heated line

Illustration 17 g06044238
Typical example
(1) NOx sensors
(2) DEF heated line

i07865023

Illustration 16 g06044127
Typical example Product Description
(1) DEF pump electronics containing filter
(2) DEF tank header
(3) DEF filler cap The Perkins 2806F-E18TA and 2806J-E18TA
(4) DEF tank drain Industrial Engines have the following characteristics:
(5) DEF tank
• Four-stroke cycle
• Mechanically actuated, electronically controlled
fuel injection system
• Turbocharged

• Air to air charged cooled

• Aftertreatment system
The Clean Emissions Module (CEM) is constructed
of four main items, the diesel Aftertreatment
Regeneration Device (ARD) oxidation catalyst, the
diesel particulate filter, and the Selective Catalytic
Reduction (SCR). The SCR requires the use of
Diesel Exhaust Fluid (DEF) to be injected into the
system to lower the emissions from the engine. The
(DEF) is stored and controlled by the pump electronic
tank unit. The DEF tank can be installed separate
from the electronic pump unit.
M0068760-05 21
Product Information Section
Product Description

Engine Specifications • Torque rise shaping

Note: The front end of the engine is opposite the • Injection timing control
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel • System diagnostics
end. The number 1 cylinder is the front cylinder. • Aftertreatment regeneration control

• NOX reduction system control

Extra Features
The following extra features provide increased
engine fuel economy and serviceability:
• Cold starting capability

• Tampering detection
• Diagnostics

Engine Diagnostics
Illustration 18 g01387009 The engine has built-in diagnostics to ensure that all
Cylinder and valve location the components are functioning properly. Under
(A) Exhaust valve
certain conditions, the engine horsepower and the
(B) Inlet valve vehicle speed may be limited. An electronic service
tool may be used to display the diagnostic code.
Table 1
There are two categories of codes: diagnostic code
Engine Specifications and event code. These two categories of codes may
be in two different states: active and logged.
Engine 2806F and 2806J

Arrangement and Cylinders In-Line 6 cylinder Most of the diagnostic codes are logged and stored in
the ECM. For additional information, refer to
Bore 145 mm (5.7 inch) theOperation and Maintenance Manual, Engine
Diagnostic topic (Operation Section).
Stroke 183 mm (7.2 inch)

Aspiration ATAAC(1) Engine Service Life

Displacement 18.1 L (1105 cubic inch) Engine efficiency and maximum utilization of engine
Firing Order 1-5-3-6-2-4
performance depend on the adherence to proper
operation and maintenance recommendations. In
Rotation (flywheel end) Counterclockwise addition, use recommended fuels, coolants, and
lubricants. Use the Operation and Maintenance
(1) Air-to-air aftercooled Manual as a guide for required engine maintenance.

Electronic Engine Features Expected engine life is predicted by the average

power that is demanded. The average power that is
demanded is based on fuel consumption of the
The engine is designed for electronic controls. The engine over a time. Reduced hours of operation at
integral on board computer controls the operation of full throttle and/or operating at reduced throttle
the engine. Current operating conditions are settings result in a lower average power demand.
monitored. The Electronic Control Module (ECM) Reduced hours of operation will increase the length
controls the response of the engine to these of operating time before an engine overhaul is
conditions and to the demands of the operator. These required. For more information, refer to the Operation
conditions and operator demands determine the and Maintenance Manual, “Overhaul Considerations”
precise control of fuel injection by the ECM. The topic.
electronic engine control system provides the
following features:
Aftermarket Products and Perkins
• Engine speed governor Engines
• Automatic air/fuel ratio control
Perkins does not warrant the quality or performance
of non-Perkins fluids and filters.
22 M0068760-05
Product Information Section
Product Description

When auxiliary devices, accessories, or

consumables (filters, additives, catalysts) which are
made by other manufacturers are used on Perkins
products, the Perkins warranty is not affected simply
because of such use.
However, failures that result from the installation
or use of other manufacturers devices,
accessories, or consumables are NOT Perkins
defects. Therefore, the defects are NOT covered
under the Perkins warranty.
M0068760-05 23
Product Information Section
Product Identification Information

Product Identification
Information
i06601446

Plate Locations and Film

Locations

Illustration 20 g01403841
Serial number plate

The following information is stamped on the serial

number plate: engine serial number, engine model,
and arrangement number.
The engine information plate is on top of the valve
cover near the middle of the engine.
The following information is on the information plate:
engine serial number, engine model, engine
Illustration 19 g06040639 arrangement number, maximum altitude of the
engine that is necessary to achieve the rated power,
(1) Serial number plate
(2) Information plate horsepower, high idle, full load rpm, fuel settings, and
other information
The engine serial number plate is on the right side of The Clean Emission Module (CEM) identification
the engine block, toward the back. plate is on the bracket assembly on the CEM.
24 M0068760-05
Product Information Section
Emissions Certification Film

Illustration 21 g06040627 Illustration 23 g06040642

(3) CEM Identification plate Typical example
(4) PETU Plate location

Illustration 22 g02236574
CEM identification plate Illustration 24 g03049116
Typical example PETU serial plate
The CEM identification plate contains the following
information: part number, serial number, change Record the information on the CEM and PETU serial
level, and configuration ID code. This information plates. The information will be required by your
may be needed by the Perkins distributor when Perkins distributor to identify replacement part
inquiries are being made on the CEM. numbers.

Pump Electronic Tank Unit (PETU) i05951816

and Pump Electronic Unit (PEU) Emissions Certification Film

Note: Some applications may not have a diesel
exhaust fluid tank installed into to the electronic unit.
Note: This information is pertinent in the United
States, in Canada and in Europe.
The emissions label is located on the top of the valve
mechanism cover.
M0068760-05 25
Operation Section
Lifting and Storage

Operation Section

Lifting and Storage

i07433049

Product Lifting

Illustration 25 g00103219

NOTICE
Always inspect lifting eyebolts and all other lifting
equipment for damage before performing any lifting.
Never bend the eyebolts and the brackets. Never
perform product lifting if components are damaged.
Only load the eyebolts and the brackets under ten-
sion. Remember that the capacity of an eyebolt is
less as the angle between the supporting members
and the object becomes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting the fixtures to obtain
proper balance and safety.
To remove the engine ONLY, use the lifting eyes that
are on the engine.
Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting
eyes and/or the engine make the lifting eyes and the
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Perkins distributor for information
regarding fixtures for proper engine lifting.
26 M0068760-05
Operation Section
Product Lifting

Engine Lifting

Illustration 26 g06044076
Typical example
(1) Engine lifting eyes
M0068760-05 27
Operation Section
Product Storage

Use an appropriate spreader set so that lifting chains Ensure that all 4 lifting eyes are used when lifting the
are perpendicular to the engine. CEM. Only use the lifting eyes (1) and lifting eyes (2)
for lifting the CEM, refer to illustration 27 .
Radiator Only
Pump Electronic Tank Unit (PETU)
Detach the radiator, and mounting bracket at the
engine front support. Add eyebolts or lifting brackets
to the threaded holes marked for lifting.

Clean Emission Module (CEM)

Lifting

Illustration 28 g06041037
Typical example
(1) PETU lifting eyes

i06605082

Product Storage
(Engine and Aftertreatment)

Your Perkins distributor can help in preparing the

engine for extended storage periods.
Illustration 27 g06042325
Typical example Some applications, the engine can be equipped with
delayed engine shutdown. Allow at least 2 minutes
(1) CEM lifting eyes
(2) CEM lifting eyes
after the engine has stopped before you turn the
battery disconnect switch to OFF. Disconnecting the
battery power too soon will prevent purging of the
DEF fluid lines after the engine is shut down. Also,
during the 2 minutes the engine electronic control
module is active storing information from the engine
and aftertreatment sensors.

Condition for Storage

An engine can be stored for up to 6 months provided
all the recommendation are adhered to.
28 M0068760-05
Operation Section
Engine and Aftertreatment

Engine Open the fuel tank drain valve to drain any water
and dirt from the fuel tank. Apply a spray of
1. Clean the engine of any dirt, rust, grease, and oil. calibration fluid or kerosene at the rate of
Inspect the exterior. Paint areas that contain paint 30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
damage with a good quality paint. capacity to prevent rust in the fuel tank. Add
0.15 mL per L (.02 oz per 1 gal US) of commercial
2. Remove dirt from the air cleaners. Check all seals,
biocide such as Biobor JF to the fuel.
gaskets, and the filter element for damage.
Apply a small amount of oil to the threads on the
3. Apply lubricant to all points in this Operation and
fuel tank filler neck and install the cap. Seal all
Maintenance Manual, “Maintenance Interval
openings to the tank to prevent evaporation of the
Schedule”.
fuel and as a preservative.
4. Drain the crankcase oil. Replace the crankcase oil
9. Remove the fuel injectors. Apply 30 mL (1 oz) of
and change the oil filters. For the proper
the mixture of oils (50 percent VCI oil and 50
procedure, refer to this Operation and
percent engine oil) into each cylinder.
Maintenance Manual.
Use a bar or a turning tool to turn over the engine
5. Add Volatile Corrosion Inhibitor (VCI) oil to the
slowly. This procedure puts the oil on the cylinder
crankcase oil. The volume of VCI oil in the
walls. Install all fuel injectors and tighten to the
crankcase oil should be 3 to 4 percent.
correct torque. Refer to Disassembly and
Note: If the engine crankcase is full, drain enough Assembly Manual for more information.
engine oil so the mixture can be added.
10. Spray a thin amount of a mixture of 50 percent
6. Remove the air filter elements. Turn the engine at VCI oil and 50 percent engine oil onto the following
cranking speed with the throttle control in FUEL components: flywheel, ring gear teeth, and starter
OFF position. Use a sprayer to add a mixture of 50 pinion. Install the covers to prevent evaporation of
percent VCI oil and 50 percent engine oil into the the vapors from the VCI oil.
air inlet or turbocharger inlet. 11. Apply a heavy amount of Multipurpose Grease to
all outside parts that move, such as rod threads,
Note: The mixture of VCI oil can be added to the inlet
by removing the plug for checking turbocharger boost ball joints, linkage.
pressure. The minimum application rate for the VCI
Note: Install all covers. Ensure that tape has been
oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of installed over all openings, air inlets, exhaust
engine displacement.
openings, the flywheel housing, the crankcase
breathers, the dipstick tubes.
7. Use a sprayer to apply a mixture of 50 percent VCI
oil and 50 percent crankcase oil into the exhaust Ensure that all covers are airtight and
openings. The minimum application rate for the oil weatherproof. Use a waterproof weather resistant
mixture is 5.5 mL per L (3 oz per 1000 cu in) of tape such as Kendall No. 231 or an equivalent. Do
engine displacement. Seal the exhaust pipe and not use duct tape. Duct tape will only seal for a
seal any drain holes in the muffler. short time.
8. Remove the fuel from the secondary fuel filter 12. Under most conditions, removing the batteries is
housing. Alternately, empty and reinstall the spin- the best procedure. As an alternative, place the
on fuel filter element to remove any dirt and water. batteries in storage. As needed, periodically
Drain any sleeve metering fuel pump. charge the batteries whilst the batteries are in
Clean the primary fuel filter. Fill with calibration storage.
fluid or kerosene. Install the primary fuel filter and If the batteries are not removed, wash the tops of
operate the priming pump. This procedure will the batteries until the tops are clean. Apply an
send clean oil to the secondary filter and the electrical charge to the batteries to obtain a
engine. specific gravity of 1.225.
Disconnect the battery terminals. Place a plastic
cover over the batteries.
13. Remove the drive belts from the engine
M0068760-05 29
Operation Section
Engine and Aftertreatment

14. Place a waterproof cover over the engine. Ensure 6. Use a bar or a turning tool to turn the engine in the
that the engine cover is secure. The cover should normal direction of rotation. The procedure
be loose enough to allow air to circulate around ensures that no hydraulic locks or resistance exist.
the engine to prevent damage from condensation.
7. Before starting the engine, remove the valve cover
15. Attach a tag with the storage date to the engine. or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism to
16. Remove the waterproof cover at 2 month or 3-
prevent damage to the mechanism.
month intervals to check the engine for corrosion.
If the engine has signs of corrosion, repeat the
protection procedure.

Coolant System
Completely fill the cooling system before storage.
Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for more information about
coolants.

Aftertreatment
The engine must be allowed to perform a Diesel
Exhaust Fluid (DEF) purge before the battery
disconnect switch is turned off. Some applications,
the engine can be equipped with delayed engine
shutdown. Allow 2 minutes after the engine has
stopped before disconnecting the battery disconnect
switch.
The exhaust outlet of the aftertreatment must be
capped. To prevent damage to the exhaust outlet
connection during storage, the weight of the CEM
must not act on the exhaust outlet.
1. Ensure normal engine shutdown, allow the DEF to
be purged. Do not disconnect the battery
disconnect switch, allow 2 minutes after key off
before disconnection.
Illustration 29 g06042459
2. Fill the tank with DEF that meets all the Typical example
requirement defined in ISO 22241-1.
(1) Plug
3. Ensure that all DEF lines and electrical connection
are connected prior to prevent crystal from 8. If an engine is stored for more than 1 year, Perkins
forming. recommends Pre lubrication of the engine to avoid
dry starting. Use a suitable pump to put engine oil
4. Ensure that the DEF filler cap is correctly installed. into the engine oil system.
Remove Engine from Storage The pump will need to create a minimum pressure
within the engine of 0.25 bar (3.6 psi). This
1. Remove all outside protective covers. pressure is needed for 15 seconds to lubricate the
internal surfaces.
2. Change the oil and filters.
3. Check the condition of the fan and alternator belts.
Replace the belts, if necessary. Refer to this
Operation and Maintenance Manual, “Belts -
Inspect/Adjust/Replace” for the correct procedure.
4. Replace the fuel filter elements.
5. Remove the plastic covers from the air cleaner
elements.
30 M0068760-05
Operation Section
Engine and Aftertreatment

Remove one of the plugs shown in illustration 29 4. If the fault continues to stay active, refer to
to connect to the engine oil system. The Troubleshooting for more information.
connection required is 9/16" x 18 tpi. Ensure that Table 2
the correct oil specification is used, refer to this DEF Storage
Operation and Maintenance Manual, “Fluid
Recommendations” for more information. After the Temperature Duration
engine internal surfaces have been lubricated, 10° C (50° F) 36 months
remove connector and install plug (1). Tighten plug
to a torque of 30 N·m (265 lb in). Perkins 25° C (77° F) 18 months
recommends that the procedure must be 30° C (86° F) 12 months
performed in a minimum ambient temperature of
35° C (95° F)(1) 6 months
10° C (50° F).
(1) At 35° C, significant degradation can occur. Check every batch
9. Check the condition of all rubber hoses. Replace before use.
any worn hoses. Replace any damaged hoses.
10. Before start-up, test the cooling system for a 3
percent to a 6 percent concentration of coolant
conditioner. Add liquid coolant conditioner or a
coolant conditioner element, if equipped.
Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.
Prime the engine with clean diesel fuel before
starting.
11. Ensure that the cooling system is clean. Ensure
that the system is full. Ensure that the system has
the correct amount of supplemental cooling
system conditioner.
12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.

Remove Aftertreatment from Storage

DEF has a limited life, refer to table 2 for the time and
temperature range. DEF that is outside this range
MUST be replaced.
On removal from storage the DEF quality in the tank
must be tested with a refractometer. The DEF in the
tank must meet the requirements defined in ISO
22241-1 and comply with table 2 .
1. If necessary, drain the tank and fill with DEF that
meets ISO 22241-1.
2. Replace the DEF filter, refer to this Operation, and
Maintenance Manual, “Diesel Exhaust Fluid Filter-
Clean/Replace”.
3. Ensure that the drive belt is correctly installed.
Ensure that all engine coolant and engine oil has
the correct specification and grade. Ensure that
the coolant and the engine oil are at the correct
level. Start the engine. If a fault becomes active
turn off the engine, allow 2 minutes for the DEF
system to purge, then restart the engine.
M0068760-05 31
Operation Section
Features and Controls

Features and Controls Note: Some items have been removed from engine
for clarity.
i06163203

Monitoring System

The monitoring system is designed to alert the

operator to an immediate problem with any of the
engine systems that are monitored. The monitoring
system is also designed to alert the operator to an
impending problem with any of the engine systems
that are monitored. The monitoring system can be
accessed by the electronic service tool. For more
information on the electronic service tool, refer to
Troubleshooting , “Electronic Tools”.

Monitoring System Indicators

Engine Malfunction – This indicator
illuminates when there is a fault with the
engine or after treatment system.
Engine STOP – This indicator will
illuminate solid when a level 3 warning
fault has been detected by the
monitoring system.

Diesel Particulate Filter (DPF) – This

indicator will illuminate in order to show
that a regeneration is needed.

Regeneration Active – This indicator will

illuminate in order to show that a
regeneration is active and exhaust
temperatures are elevated.
Diesel Exhaust Fluid (DEF) Level – This
gauge shows the amount of DEF in the
DEF tank.
Emission Malfunction Indicator – This
indicator will illuminate when an
emissions system related to DEF or SCR
has failed. Refer to Operation and Maintenance
Manual, “Selective Catalytic Reduction Warning
System” for more information.

i06617615

Sensors and Electrical

Components

The illustrations within the following sections are

typical location of the sensors or electrical
components for an industrial engine. Specific
engines may appear different due to differences in
applications.
32 M0068760-05
Operation Section
Sensors and Electrical Components

Engine

Illustration 30 g06048161
Typical example
(1) Secondary Speed/timing sensor (7) NRS temperature sensor (13) Fuel pressure sensor
(2) Boost pressure sensor (8) Air control solenoid valve (14) Fuel temperature sensor
(3) Inlet air temperature sensor (9) Electronic control module (15) Primary speed/timing sensor
(4) NOx Reduction System (NRS) solenoid (10) Starter solenoid and starting motor (16) Alternator
(5) NRS pressure sensor (11) Oil pressure sensor (17) Refrigerant compressor
(6) NRS differential pressure sensor (12) Barometer pressure sensor
M0068760-05 33
Operation Section
Sensors and Electrical Components

Illustration 31 g06048567
Typical example
(18) Coolant temperature sensor
34 M0068760-05
Operation Section
Sensors and Electrical Components

Illustration 32 g06049146
Typical example
(19) Location for Top Dead Center (TDC) probe

Aftertreatment System

Illustration 33 g06048751
Typical example
(1) Diesel Exhaust Fluid (DEF) injector (3) Coil for spark plug
(2) Temperature sensor
M0068760-05 35
Operation Section
Sensors and Electrical Components

(4) Diesel Particulate Filter (DPF) (7) 40-Pin connector (10) Fuel main pressure sensor
Differential pressure sensor (8) Selective Catalytic Reduction (SCR) (11) Identification Module
(5) DPF pressure sensor temperature sensor (12) Temperature sender for Aftertreatment
(6) Temperature sender (9) Fuel pilot pressure sensor Regeneration Device (ARD)

Pump Electronic Tank Unit (PETU)

Illustration 34 g03393959
Typical example
(1) DEF Level Sensor and DEF Temperature (3) Customer Connections (6) Voltage Limiting Protection Module
Sensor (4) Dosing Control Module
(2) Coolant Diverter Valve (5) Relays
36 M0068760-05
Operation Section
Battery Disconnect Switch

i05422613 The battery disconnect switch and the engine start

switch perform different functions. The entire
Battery Disconnect Switch electrical system is disabled when you turn the
battery disconnect switch to the OFF position. The
(If Equipped) battery remains connected to the electrical system
when you turn the engine start switch to the OFF
position.
Turn the battery disconnect switch to the OFF
position and remove the key when you service the
electrical system or any other engine components.
Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key after
you operate the engine. This will prevent the battery
from being discharged. The following problems can
cause battery discharge:

• short circuits
• current draw via some components
• vandalism

Illustration 35 g03422039 i07507902

NOTICE Selective Catalytic Reduction

Do not turn off the battery disconnect switch until the Warning System
indicator lamp has turned off. If the switch is turned
off when the indicator lamp is illuminated the Diesel
Exhaust Fluid (DEF) system will not purge the DEF. If
the DEF does not purge, DEF could freeze and dam- The selective catalytic reduction (SCR) system is a
age the pump and lines. system used to reduce NOx emissions from the
engine. Diesel exhaust fluid (DEF) is pumped from
the DEF tank and is sprayed into the exhaust stream.
NOTICE The DEF reacts with the SCR catalyst to reduce NOx
Never move the battery disconnect switch to the OFF and leaves a nitrogen and water vapor. The Exhaust
position while the engine is operating. Serious dam- Gas Recirculation (EGR) system cools, measures,
age to the electrical system could result. and introduces recalculated exhaust gas into the
intake manifold to aid in NOx reduction.

Battery Disconnect Switch – The battery The engine and emissions control system shall be
operated, used, and maintained in accordance with
disconnect switch can be used in order the instructions provided to the end user to maintain
to disconnect the battery from the the emissions performance of the engine within the
engines electrical system. The key must be requirements applicable to the category of the
inserted into the battery disconnect switch engine. No deliberate tampering with, or misuse of
before the battery disconnect switch can be the engine emissions control system should take
turned. place. In particular regarding deactivating, or not
maintaining the SCR system.
ON – To activate the electrical system,
insert the disconnect switch key and NOTICE
turn the battery disconnect switch Stopping the engine immediately after the engine has
clockwise. The battery disconnect switch must been working under load can result in overheating of
be turned to the ON position before you start the SCR components.
engine.
Refer to the Operation and Maintenance Manual,
OFF – To deactivate the electrical “Engine Stopping” procedure to allow the engine to
system, turn the battery disconnect cool and to prevent excessive temperatures in the
switch counterclockwise to the OFF turbocharger housing and the DEF injector.
position.
M0068760-05 37
Operation Section
Selective Catalytic Reduction Warning System

Safe Harbor Mode (European Union) – Safe

NOTICE Harbor Mode is a 30 minute engine run time period
Allow at least 2 minutes after shutting down the en-
gine before you turn the battery disconnect switch to that the engine can be operated with full power after
OFF. Disconnecting the battery power too soon will reaching a level 3 inducement. Once in level 3
prevent purging of the DEF lines after the engine is inducement, the operator can perform a key cycle
shut down. and the engine will enter Safe Harbor Mode. Safe
Harbor Mode can only be implemented up to three
times.

Definitions
NOTICE
Observe the following definitions. It is essential to take prompt action to rectify any in-
correct operation, use, or maintenance of the emis-
Self-correct – Fault condition no longer exists. An sions SCR control system in accordance with the
active fault code will no longer be active. rectification measures indicated by the warnings
listed on the following pages.
Notification – Action taken by the system to alert the
operator of pending Inducement.
Inducement – Engine derates, vehicle speed limits,
or other actions intended to prompt the operator to
repair or maintain the emission control system.
Inducement Categories – The Inducements are
separated into categories. DEF Level has its own
inducement fault codes and is separate from the
other inducement categories. Whilst DEF level
inducements are simplybased on the DEF level, the
other inducement categories are based on escalating
time. The escalating time inducements will always
have an associated fault code along with the
inducement fault code. The associated fault is the
root cause. The escalating time inducement fault
code is just an indicator of what level of inducement
the engine is in and how much time remains until the
next level of inducement. There are three inducement Illustration 36 g03676102
categories (two for European Union) that will trigger DEF Level Normal
an escalating time inducement fault code.
Inducement Strategy for DEF Level
Note: The associated codes for each of the
escalating time categories can be found in the
(European Union)
Troubleshooting Guide under SCR Warning System
Problem.
First occurrence – When an escalating time
inducement fault code becomes active for the first
time.
Repeat occurrence – When any escalating time
inducement fault code becomes active again within
40 hours of the first occurrence. Engine must run for
40 hours without tripping any escalating time
inducement fault before it can get back on first
occurrence times.
Safe Harbor Mode (Worldwide) – Safe Harbor
Mode is a 20 minute engine run time period that the
engine can be operated with full power after reaching
a level 3 inducement. Once in level 3 inducement, the Illustration 37 g03676107
operator can perform a key cycle and the engine will
enter Safe Harbor Mode. Safe Harbor Mode can only If the DEF level falls below 20%, an amber indicator
be implemented once. Safe Harbor Mode is not will illuminate next to the DEF level gauge on the
allowed for DEF level inducements with Worldwide dash. To avoid further inducements, turn the key to
configuration. the OFF position and add DEF to the DEF tank.
38 M0068760-05
Operation Section
Selective Catalytic Reduction Warning System

Illustration 38 g03676111 Illustration 40 g03676127

If the DEF level falls below 13.5%, a level 1 Reduced Time

inducement event will occur. The check engine lamp
and the emissions malfunction indicator lamp will If the ECM is configured to “Reduced Time” and the
illuminate. The amber indicator next to the DEF level DEF level is 0%, the engine will be in level 3
gauge on the dash will remain lit. inducement. The check engine lamp and emissions
malfunction indicator lamp will illuminate and flash at
a fast rate. A red stop lamp will illuminate solid. The
DEF level gauge amber lamp will remain lit. The
engine will have a 100% derate and be limited to
1000 rpm or low idle, whichever is greater. If the final
inducement action in ET is set to “Idle Down” , then
the engine will continue to idle at derated condition. If
set to “Shutdown” , engine will shut down after 5
minutes. Safe Harbor Mode is allowed for three key
cycles. After Safe Harbor Mode is completed, the
engine will return to idle or shut down. If in shutdown
configuration, the engine may be restarted, but will
only run for 5 minutes at derated condition before
shutting down again. This action will continue until
the issue is resolved.

Illustration 39 g03676123 Note: Turn the key to the OFF position and add DEF
to the DEF tank to reset the DEF level inducement.
Reduced Performance
When the ECM is configured to "Reduced Inducement Strategy for Escalating
Performance" and the DEF level is below 1%, the
engine will be in level 2 inducement. The check
Time Inducement Faults (European
engine lamp and emissions malfunction indicator Union)
lamp will illuminate and flash slowly. The DEF level
gauge amber lamp will remain lit. The engine will
have a 50% derate. When the DEF tank has been
emptied of all DEF, the engine will have a 100%
derate and be limited to 1000 rpm or low idle,
whichever is greater. No further inducement action
will occur for "Reduced Performance" configuration.
Safe Harbor Mode is allowed for three key cycles.
Reduced Time
Illustration 41 g03677836
When the ECM is configured to “Reduced Time” and
the DEF level is below 7.5%, the engine will be in Reduced Performance
level 2 inducement. The check engine lamp and
emissions malfunction indicator lamp will illuminate
and flash slowly. The DEF level gauge amber lamp
will remain lit.
M0068760-05 39
Operation Section
Selective Catalytic Reduction Warning System

The check engine and emissions malfunction If the inducement is a result of a category 2 fault, then
indicator lamp will illuminate for a level 1 inducement- a level 2 inducement will occur for a duration of 5
related fault. There are two inducement categories. If hours. For repeat occurrence, a category 2 level 2
the inducement is a result of a category 1 fault, then a inducement fault will occur for a duration of 1 hour.
level 1 inducement will occur for a duration of 36
hours. If the inducement is a result of a category 2
fault, then a level 1 inducement will occur for a
duration of 10 hours. There is no repeat occurrence
for level 1 faults.
Reduced Time
The check engine and emissions malfunction
indicator lamp will illuminate for a level 1 inducement-
Illustration 43 g03676141
related fault. There are two inducement categories. If
the inducement is a result of a category 1 fault, then a
level 1 inducement will occur for a duration of 18 Reduced Time
hours. If the inducement is a result of a category 2 If configured to “Reduced Time” and a fault condition
fault, then a level 1 inducement will occur for a exists for the entire duration of inducement level 2,
duration of 5 hours. There is no repeat occurrence for the strategy advances to inducement level 3.
level 1 faults. Inducement level 3 has the same actions for all
categories. The check engine lamp and emissions
malfunction indicator lamp will flash at a fast rate. A
red stop lamp will also illuminate solid. The engine
will have a 100% derate and be limited to 1000 rpm
or low idle, whichever is greater. If the final
inducement action in ET is set to “Idle Down” , then
engine will continue to idle at derated condition. If set
to “Shutdown” , engine will shut down after 5 minutes.
A key cycle will allow safe harbor mode to initiate.
Illustration 42 g03676138 Safe harbor is allowed up to three times. After safe
harbor, the engine will be in level 3 final inducement.
Reduced Performance If set to “Shutdown” , the engine may be restarted,
If a fault condition exists for the entire duration of but will only run for 5 minutes at derated condition
inducement level 1, the strategy advances to before shutting down again. This action will continue
inducement level 2. The check engine lamp and the until the issue is resolved.
emissions malfunction indicator lamp will illuminate
and flash slowly. If the inducement is a result of a Note: Contact your Perkins dealer for repairs if a fault
category 1 fault, then a level 2 inducement will occur occurs.
for a duration of 64 hours for first occurrence. For
repeat occurrence, a category 1 level 2 inducement Inducement Strategy for DEF Level
fault will occur for a duration of 5 hours.
(Worldwide)
If the inducement is a result of a category 2 fault, then
a level 2 inducement will occur for a duration of 10
hours. For repeat occurrence, a category 2 level 2
inducement fault will occur for a duration of 2 hours.
The engine will have a 50% derate. If the fault is not
corrected before the inducement duration ends, the
engine will become 100% derated and be limited to
1000 rpm or low idle, whichever is greater. No further
inducements will occur for “Reduced Performance”
configuration. Safe Harbor Mode is allowed for three
key cycles.
Reduced Time
If a fault condition exists for the entire duration of
inducement level 1, the strategy advances to
inducement level 2. The check engine lamp and the
emissions malfunction indicator lamp will illuminate Illustration 44 g03676164
and flash slowly. If the inducement is a result of a
category 1 fault, then a level 2 inducement will occur If the DEF level falls below 20%, an amber indicator
for a duration of 18 hours for first occurrence. For will illuminate next to the DEF level gauge on the
repeat occurrence, a category 1 level 2 inducement dash. To avoid inducements, turn the key to the OFF
fault will occur for a duration of 108 minutes. position and add DEF to the DEF tank.
40 M0068760-05
Operation Section
Selective Catalytic Reduction Warning System

Illustration 45 g03676169 Illustration 47 g03676210

If the DEF level falls below 13.5%, a level 1 If the ECM is configured to “Reduced Performance”
inducement event will occur. The check engine lamp and the DEF tank has been emptied of all DEF, the
and the emissions malfunction indicator lamp will engine will be in a level 3 final inducement. If the
illuminate. The amber indicator next to the DEF level ECM is configured to “Reduced Time” and the DEF
gauge on the dash will remain lit. level is 3%, the engine will be in a level 3 final
inducement. The check engine lamp and the
emissions malfunction indicator lamp will flash at a
fast rate and a red stop lamp will illuminate solid. The
engine will be taken too low idle or will be shut down.
Once shut down, the engine can be restarted for 5
minute periods at reduced speed and torque. If set to
idle, the engine will idle indefinitely at reduced torque.
The amber indicator next to the DEF level gauge on
the dash will remain lit.
Note: Turn the key to the OFF position and add DEF
to the DEF tank to reset the DEF level inducement.

Inducement Strategy for Escalating

Time Inducement Faults
Illustration 46 g03676174
(Worldwide)
If the DEF level is below 7.5%, a level 2 inducement
event will occur. The check engine lamp and the
emissions malfunction indicator lamp will illuminate
and flash slowly. The amber indicator next to the DEF
level gauge on the dash will remain lit. If the ECM is
configured to “Reduced Performance” and the DEF
level has reached 1%, the machine will be limited to
75% torque.

Illustration 48 g03676215

Reduced Performance
The check engine and emissions malfunction
indicator lamp will illuminate for a level 1 inducement-
related fault. There are three inducement categories.
If the inducement is a result of a category 1 fault, then
a level 1 inducement will occur for a duration of 2.5
hours for first occurrence. For repeat occurrence, a
category 1 level 1 inducement fault will occur for a
duration of 5 minutes.
M0068760-05 41
Operation Section
Selective Catalytic Reduction Warning System

If the inducement is a result of a category 2 fault, then The check engine and emissions malfunction
a level 1 inducement will occur for a duration of 10 indicator lamp will illuminate for an inducement-
hours. There is no repeat occurrence for category 2, related fault. There are three inducement categories.
level 1 inducement faults. If the inducement is a result of a category 1 fault, then
a level 1 inducement will occur for a duration of 2.5
If the inducement is a result of a category 3 fault, then hours for first occurrence. For repeat occurrence, a
a level 1 inducement will occur for a duration of 36 category 1 level 1 inducement fault will occur for a
hours. There is no repeat occurrence for category 3, duration of 5 minutes.
level 1 inducement faults.
If the inducement is a result of a category 2 fault, then
Reduced Time The check engine and emissions a level 1 inducement will occur for a duration of 5
malfunction indicator lamp will illuminate for a level 1 hours. There is no repeat occurrence for category 2,
inducement-related fault. There are three inducement level 1 inducement faults.
categories. If the inducement is a result of a category
1 fault, then a level 1 inducement will occur for a If the inducement is a result of a category 3 fault, then
duration of 2.5 hours for first occurrence. For repeat a level 1 inducement will occur for a duration of 18
occurrence, a category 1 level 1 inducement fault will hours. There is no repeat occurrence for category 3,
occur for a duration of 5 minutes. level 1 inducement faults.
If the inducement is a result of a category 2 fault, then
a level 1 inducement will occur for a duration of 5
hours. There is no repeat occurrence for category 2,
level 1 inducement faults.
If the inducement is a result of a category 3 fault, then
a level 1 inducement will occur for a duration of 18
hours. There is no repeat occurrence for category 3,
level 1 inducement faults.
Illustration 50 g03676218

If a fault condition exists for the entire duration of

inducement level 2, the strategy advances to
inducement level 3. Inducement level 3 has the same
actions for all categories. The check engine lamp and
the emissions malfunction indicator lamp will flash at
a fast rate. A red stop lamp will illuminate solid. The
engine will have a 100% derate and be limited to
Illustration 49 g03676215
1000 rpm or low idle, whichever is greater. If the final
inducement action in ET is set to "Idle Down", then
engine will continue to idle at derated condition. If set
Reduced Performance If a fault condition exists for
the entire duration of inducement level 1, the strategy to "Shutdown" , engine will shut down after 5
advances to inducement level 2. The check engine minutes. A key cycle will allow safe harbor mode to
and emissions malfunction indicator lamp will initiate. Safe harbor is only allowed once. After safe
illuminate and flash slowly for a level 2 inducement- harbor, the engine will be in level 3 final inducement.
related fault. The engine will have a 50% derate. If If set to "Shutdown", the engine may be restarted, but
the inducement is a result of a category 1 fault, then a will only run for 5 minutes at derated condition before
level 2 inducement will occur for a duration of 70 shutting down again. This action will continue until
minutes for first occurrence. For repeat occurrence, a the issue is resolved.
category 1 level 2 inducement fault will occur for a
duration of 5 minutes. Note: Contact your Perkins dealer for repairs if a fault
occurs.
If the inducement is a result of a category 2 fault, then
a level 2 inducement will occur for a duration of 10
hours. For repeat occurrence, a category 2 level 2
inducement fault will occur for a duration of 2 hours.
If the inducement is a result of a category 3 fault, then
a level 2 inducement will occur for a duration of 64
hours. For repeat occurrence, a category 3 level 2
inducement fault will occur for a duration of 5 hours.
Reduced Time
42 M0068760-05
Operation Section
Engine Diagnostics

Engine Diagnostics i06193980

i05194988
Configuration Parameters
Self-Diagnostics The engine electronic control module (ECM) has two
types of configuration parameters. The system
configuration parameters and the customer specified
Perkins Electronic Engines have the capability to parameters.
perform a self-diagnostics test. When the system
detects an active problem, a diagnostic lamp is The electronic service tool is required in order to alter
activated. Diagnostic codes will be stored in the configuration parameters.
permanent memory in the Electronic Control Module
(ECM). The diagnostic codes can be retrieved by System Configuration Parameters
using Perkins electronic service tools.
Some installations have electronic displays that System configuration parameters affect the
provide direct readouts of the engine diagnostic emissions of the engine or the power of the engine.
codes. Refer to the manual that is provided by the System configuration parameters are programmed at
OEM for more information on retrieving engine the factory. Normally, system configuration
diagnostic codes. parameters would never require changing through
the life of the engine. System configuration
Active codes represent problems that currently exist. parameters must be reprogrammed if an ECM is
These problems should be investigated first. replaced. System configuration parameters do not
require reprogrammed if the ECM software is
Logged codes represent the following items: changed. Factory passwords are required to change
these parameters.
• Intermittent problems

• Recorded events
• Performance history
The problems may have been repaired since the
logging of the code. These codes do not indicate that
a repair is needed. The codes are guides or signals
when a situation exists. Codes may be helpful to
troubleshoot problems.
When the problems have been corrected, the
corresponding logged fault codes should be cleared.

i05406659

Fault Logging

The system provides the capability of Fault Logging.

When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be
logged in the memory of the ECM. The codes that
have been logged by the ECM can be identified by
the electronic service tool. The active codes that
have been logged will be cleared when the fault has
been rectified or the fault is no longer active. The
following logged faults cannot be cleared from the
memory of the ECM without using a factory
password: Overspeed, low engine oil pressure, high
engine coolant temperature, and aftertreatment
codes.
M0068760-05 43
Operation Section
Configuration Parameters

Table 3
System Configuration Parameters

Configuration Parameters Record

Engine Serial Number

Rating

Full Load Setting

Full Torque Setting

ECM Software Release Date

Customer Specified Parameters

Customer specified parameters allow the engine to
be configured to the exact needs of the application.
The electronic service tool is required in order to alter
the customer configuration parameters.
Customer parameters may be changed repeatedly as
operational requirements change.
Table 4
Customer Specified Parameters

Specified Parameters Record

Top Engine Limit 1900 rpm

Low Idle Speed 600 rpm

Top Engine Limit 2090 rpm

Engine Acceleration Rate 2000 rpm/s

Engine Speed Decelerating Ramp Rate 2000rpm/s

Ether Start Aid Configuration Not Installed

Crankcase Pressure Sensor Installation Status Not Installed

Ambient Air Temperature Sensor Installation Status Not Installed

Engine Idle Shutdown Enable Status Disabled

Engine Idle Shutdown Delay Time 5.0 min

Engine Idle Shutdown Ambient Temperature Override Enable Status Disabled or Not Installed

Delayed Engine Shutdown Enable Status Disabled

Delayed Engine Shutdown Maximum Time 7.0 min

Aftertreatment #1 DEF Dosing Line Purge Required Air Temperature 5° C (41° F)

Threshold
Delayed Engine Shutdown Aftertreatment Outlet Gas Temperature 400° C (752° F)
Threshold
Engine Performance Run Out Control Configuration Not Installed

Engine Governor Mode Override Switch Installation Status Not Installed

(continued)
44 M0068760-05
Operation Section
Configuration Parameters

(Table 4, contd)
Transmission Default Torque Limit Reset Not Reset

Air Filter Restriction Switch Installation Status Not Installed

Air Filter Restriction Switch Configuration Normally Open

Intermediate Engine Speed 1400. rpm

Air Shutoff Disabled

Air Intake Shutoff Detection Installation Status Not Installed
Coolant Level Sensor Not Installed
Engine Retarder Enable Command Disabled

Auxiliary Temperature Sensor Installation Status Not Installed

Auxiliary Temperature Sensor #2 Installation Status Not Installed

Auxiliary Pressure Sensor Installation Status Not Installed

Engine Governor Primary Mode Configuration Speed Control

DPF Regeneration Enable Input Configuration CAN Input

Limp Home Desired Engine Speed 1200. rpm

Limp Home Engine Speed Ramp Rate 200. rpm/s

Throttle Input Low Idle Duty Cycle Setpoint 10 Percent

Throttle Input High Idle Duty Cycle Setpoint 90 Percent

Throttle Input #2 Low Idle Duty Cycle Setpoint 10 Percent

Throttle Input #2 High Idle Duty Cycle Setpoint 90 Percent

Throttle Failure Mode Latch Enable Status Enabled

Throttle #1 Engine Speed Droop 5 Percent

Throttle #2 Engine Speed Droop 5 Percent

Data Link Engine Speed Droop 5 Percent

Droop No Load Fuel Offset 0 Percent

Throttle Lock Feature Installation Status Not Installed

PTO Mode Set/Resume
Throttle Lock Engine Set Speed #1 600 rpm

Throttle Lock Engine Set Speed #2 600 rpm

Throttle Lock Increment Speed Ramp Rate 400. rpm/s

Throttle Lock Decrement Speed Ramp Rate 400 rpm/s

Throttle Lock Engine Set Speed Increment 10. rpm

Throttle Lock Engine Set Speed Decrement 10. rpm

Engine Fan Control Off

Engine Fan Type Configuration Variable Hydraulic

Engine Fan Speed Control Configuration Disabled or Not Installed

Engine Fan Reversing Feature Disabled

(continued)
M0068760-05 45
Operation Section
Configuration Parameters

(Table 4, contd)
Engine Fan Manual Purge Disabled

Engine Fan Suspend Purge Disabled

Engine Fan Purge Cycle Interval 1200 sec

Engine Fan Purge Cycle Duration 180.0sec

Engine Fan Control Charge Air Cooler Outlet Temperature Input Enabled
Enable
Engine Cooling Fan Maximum Air Flow Charge Air Cooler Outlet 46.6° C (116° F)
Temperature

Engine Cooling Fan Minimum Air Flow Charge Air Cooler Outlet 40° C (104° F)
Temperature

Engine Cooling Fan Control Coolant Temperature Input Enable Status Enabled

Engine Cooling Fan Maximum Air Flow Coolant Temperature 100° C (212° F)

Engine Cooling Fan Minimum Air Flow Coolant Temperature 90° C (194° F)

Engine Cooling Fan Control Transmission Oil Temperature Input Ena- Disabled
ble Status
Engine Cooling Fan Control Hydraulic Oil Temperature Input Enable Disabled
Status
Engine Cooling Fan Control Auxiliary #1 Temperature Input Enable Disabled
Status
Engine Cooling Fan Control Auxiliary #2 Temperature Input Enable Disabled
Status
Maintenance Indicator Mode Off
PM1 Interval 2500 gal

Operator Inducement Progress Configuration Reduced Performance

Operator Inducement Regulation Configuration Worldwide

Operator Inducement Emergency Override Enable Status Disabled

Operator Inducement Emergency Override Activation Not Activated

Operator Inducement Emergency Override Mode Configuration Standard

Operator Final Inducement Action Shutdown

Air Inlet Temperature Calibration Value Disabled or Not Installed

System Operating Voltage Configuration 12 V

Backup Timing Sensor Calibration Offset -0.25 Degrees

Primary Timing Sensor Calibration Offset -0.40 Degrees

46 M0068760-05
Operation Section
Engine Starting

Engine Starting • Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
i02109067 to the controls.

Before Starting Engine • Ensure that the areas around the rotating parts are
clear.

• All of the guards must be put in place. Check for

Perform the required daily maintenance and other
damaged guards or for missing guards. Repair
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can any damaged guards. Replace damaged guards
help prevent major repairs at a later date. Refer to and/or missing guards.
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for more • Disconnect any battery chargers that are not
information. protected against the high current drain that is
created when the electric starting motor (if
• For the maximum service life of the engine, make equipped) is engaged. Check electrical cables and
a thorough inspection before the engine is started. check the battery for poor connections and for
Look for the following items: oil leaks, coolant corrosion.
leaks, loose bolts and trash buildup. Remove trash
buildup and arrange for repairs, as needed. • Reset all of the shutoffs or alarm components.

• Inspect the aftercooler for loose connections and • Check the engine lubrication oil level. Maintain the
for debris buildup. oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• Inspect the cooling system hoses for cracks and
for loose clamps. • Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
• Inspect the alternator and accessory drive belts for the coolant level to the “FULL” mark on the coolant
cracks, breaks, and other damage. recovery tank.

• Inspect the wiring for loose connections and for • If the engine is not equipped with a coolant
worn wires or frayed wires. recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
• Check the fuel supply. Drain water from the water the engine is equipped with a sight glass, maintain
separator (if equipped). Open the fuel supply the coolant level in the sight glass.
valve.
• Observe the air cleaner service indicator (if
NOTICE equipped). Service the air cleaner when the yellow
All valves in the fuel return line must be open before diaphragm enters the red zone, or when the red
and during engine operation to help prevent high fuel piston locks in the visible position.
pressure. High fuel pressure may cause filter housing
failure or other damage. • Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
any electrical loads.
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air may i06092648
have entered the filter housing. Also, when fuel filters
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel Starting the Engine
system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system.

Engine exhaust contains products of combustion

which may be harmful to your health. Always
Engine exhaust contains products of combustion start and operate the engine in a well ventilated
which may be harmful to your health. Always area and, if in an enclosed area, vent the exhaust
start and operate the engine in a well ventilated to the outside.
area and, if in an enclosed area, vent the exhaust
to the outside.
M0068760-05 47
Operation Section
Starting the Engine

Starting the Engine Note: Oil pressures and fuel pressures should be in
the normal range on the instrument panel. Engines
Refer to the Owners Manual of the OEM for your type that are equipped with “WARNING” lamps do not
of controls. Use the following procedure to start the have an operating range. The “WARNING and
engine. DIAGNOSTIC” lamp (if equipped) will flash while the
engine is cranking. The lamp should turn off after
1. Place the transmission in NEUTRAL. Disengage proper engine oil pressure or fuel pressure is
the flywheel clutch in order to allow the engine to achieved. Do not apply a load to the engine or
start faster, and to reduce the draining of the increase engine rpm until the oil pressure gauge
battery. indicates at least normal pressure. Inspect the engine
for leaks and/or unusual noises.
2. Turn the ignition switch to the ON position.
If the engine is operated with a low load, the engine
During the key on, all warning lamps will illuminate
will reach normal operating temperature sooner than
for a few seconds, in order to test the circuits. If idling the engine with no load. When the engine is
any lamps do not illuminate, check the bulbs and idled in cold weather, increase the engine rpm to
replace as necessary. approximately 1000 to 1200 rpm in order to raise
engine temperature. Do not exceed the
NOTICE recommended rpm in order to increase the speed of
Do not engage the starting motor when flywheel is the warm-up. Limit unnecessary idle time to 10
turning. Do not start the engine under load. minutes.

If the engine fails to start within 30 seconds, release Starting Problems

the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again. An occasional starting problem may be caused by
one of the following items:

3. Push the start button or turn the ignition switch to • Low battery charge
the START position in order to crank the engine.
• Lack of fuel
Do not push down or hold the throttle down while
the engine is cranked. The system will • Problem with the wiring harness
automatically provide the correct amount of fuel If the engine fuel system has been run dry, fill the fuel
that is needed to start the engine. tank and prime the fuel system. Refer to the
Operation and Maintenance Manual, “Fuel System -
4. If the engine fails to start within 30 seconds, Prime” topic (Maintenance Section).
release the start button, or the ignition switch. Wait
for 2 minutes in order to allow the starting motor to
cool before attempting to start the engine again.

NOTICE
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine rpm until the oil
pressure gauge indicates normal. If oil pressure is
not indicated on the gauge within 15 seconds, DO
NOT operate the engine. STOP the engine, investi-
gate and correct the cause.

5. Allow the engine to idle for approximately 3

minutes. Idle the engine until the water
temperature gauge has begun to rise. Check all
gauges during the warm-up period.
48 M0068760-05
Operation Section
Cold Weather Starting

If the other problems are suspected, perform the Note: If the engine has not been run for several
appropriate procedure in order to start the engine. weeks, fuel may have drained. Air may have moved
into the filter housing. Also, when fuel filters have
Problems with the Wiring Harness been changed, some air will be left in the filter
housing. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” (Maintenance
Section) for more information on priming the fuel
system.

Ether Injection System (If

Equipped)
The ether injection system is controlled by the ECM.
The ECM monitors the coolant temperature, intake
air temperature, ambient air temperature, and
barometric pressure to determine when ether
injection is needed. At sea level, ether will be used if
any of the temperatures fails to exceed 0° C (32° F).
This temperature is subject to an increase as
barometric pressure increases.

Personal injury or property damage can result

from alcohol or starting fluids.

Illustration 51 g01248812
Alcohol or starting fluids are highly flammable
and toxic and if improperly stored could result in
ECM Connector J2/P2 injury or property damage.
Locate the ECM. Check the connector in order to
ensure that the connector is secure. Lightly pull each Follow the procedure in this Operation and
of the wires in the chassis harness. Maintenance Manual, “Starting the Engine”.
1. Pull each wire with approximately 4.5 kg (10 lb) of
force. The wire should remain in the connector. i07708163

2. If a wire is loose, push the wire back into the Starting with Jump Start
connector. Pull the wire again in order to ensure
that the wire is secure.
Cables
3. Start the engine. If the engine does not start, check (Do Not Use This Procedure in
for a diagnostic code and consult your Perkins Hazardous Locations that have
distributor.
Explosive Atmospheres)
i04132731

Cold Weather Starting

The connection of battery cables to a battery and
Startability will be improved at temperatures below the disconnection of battery cables from a battery
10°C (50°F) from the use of a cylinder block coolant may cause an explosion which may result in in-
heater or from other means that are used to heat the jury or death. The connection and the disconnec-
crankcase oil. Some engine applications use a jacket tion of other electrical equipment may also cause
water heater to improve startability. Use of a jacket an explosion which may result in injury or death.
water heater will help reduce white smoke and The procedures for the connection and the dis-
misfire during start-up in cold weather. connection of battery cables and other electrical
equipment should only be performed in a nonex-
plosive atmosphere.
M0068760-05 49
Operation Section
After Starting Engine

Note: The engine ECM must be powered before the

starting motor is operated or damage can occur.
Improper jump start cable connections can cause
an explosion resulting in personal injury. 4. Start the engine in the normal operating
procedure. Refer to this Operation and
Prevent sparks near the batteries. Sparks could Maintenance Manual, “Starting the Engine”.
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine. 5. Immediately after the engine is started, disconnect
the jump-start cables in reverse order.

Note: If possible, first diagnose the reason for the After jump starting, the alternator may not be able to
starting failure. Refer to Troubleshooting, “Engine recharge fully batteries that are severely discharged.
Will Not Crank and Engine Cranks But Will Not Start” The batteries must be replaced or charged to the
for further information. Make any necessary repairs. proper voltage with a battery charger after the engine
If the engine will not start only due to the condition of is stopped. Many batteries which are considered
the battery, either charge the battery, or start the unusable are still rechargeable. Refer to Operation
and Maintenance Manual, “Battery - Replace” and
engine by using another battery with jump-start
Testing and Adjusting Manual, “Battery - Test”.
cables. The condition of the battery can be
rechecked after the engine has been switched OFF.
i05359363

NOTICE After Starting Engine

Ensure that a 12 VDC or 24 VDC battery source is
used to start the engine. Never attempt to start an en-
gine from an external power source such as electric
welding equipment, which has a voltage that is un- Note: In temperatures from 0 to 60°C (32 to 140°F),
suitable for engine starting and will damage the elec- the warm-up time is approximately 3 minutes. In
trical system. temperatures below 0°C (32°F), additional warm-up
time may be required.
NOTICE When the engine is idling during warm-up, observe
Using a battery source with the same voltage as the the following conditions:
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage • Check for fluid or air leaks at idle rpm and at one-
the electrical system. half full rpm (no load on the engine) before
operating the engine under load. Operating the
Do not reverse the battery cables. The alternator can engine at idle and at one-half full rpm with no load
be damaged. Attach ground cable last and remove
is not possible in some applications.
first.
Turn all electrical accessories OFF before attaching • Operate the engine at low idle until all systems
the jump start cables. achieve operating temperatures. Check all gauges
during the warm-up period.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en- Note: Gauge readings should be observed and the
gine being started. data should be recorded frequently while the engine
is operating. Comparing the data over time will help
to determine normal readings for each gauge.
1. Turn the start switch on the stalled engine to the Comparing data over time will also help detect
OFF position. Turn off all the engines accessories. abnormal operating developments. Significant
2. Connect one positive end of the jump-start cable to changes in the readings should be investigated.
the positive cable terminal of the discharged
battery. Connect the other positive end of the
jump-start cable to the positive cable terminal of
the electrical source.
3. Connect one negative end of the jump-start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump-start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting the combustible
gases that are produced by some batteries.
50 M0068760-05
Operation Section
After Starting Engine

Extended Idle at Cold Ambient

Temperature
The engine may automatically change speeds when
the engine is idling in cold ambient temperatures
(typically less than 0° C (32° F) for extended periods.
The purpose of the automatic speed change is
threefold: to maintain the desired operation of the
NOx reduction system, to maintain the desired
operation of the regeneration system and to keep the
engine coolant warm. The engine speed may rise to
1600 rpm for as long as 20 minutes.
The high exhaust system temperature lamp may
illuminate during extended idling conditions. This
illumination signals that a diesel particulate filter
(DPF) regeneration is in progress. Regenerations
during cold ambient extended idling may only last up
to 10 minutes.
M0068760-05 51
Operation Section
Engine Operation

Engine Operation This design of DPF will require a service

maintenance interval. Refer to this Operation and
Maintenance Manual, “Maintenance Interval
i06603162 Schedule” for more information. The DPF can be
expected to function properly for the useful life of the
Engine Operation engine (emissions durability period), as defined by
regulation, subject to prescribed maintenance
requirements being followed.

Proper operation and maintenance are key factors in i07507904

obtaining the maximum life and economy of the
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be Diesel Particulate Filter
minimized and engine service life can be maximized. Regeneration
The time that is needed for the engine to reach
normal operating temperature can be less than the
time taken for a walk-around inspection.
Regeneration
The engine can be operated at the rated rpm after
the engine is started and after the engine reaches Regeneration is to increase the exhaust temperature
operating temperature. The engine will reach normal for a given time. The Aftertreatment Regeneration
operating temperature sooner during a low engine Device (ARD) creates the heat which makes
speed (rpm) and during a low-power demand. This regeneration possible. The regeneration process is
procedure is more effective than idling the engine at used to remove soot from the DPF, and warmup the
no load. The engine should reach operating Selective Catalyst Reduction (SCR) system. The
temperature in a few minutes. DPF traps both soot and ash. The ash is removed
through a manual cleaning process. Refer to
Avoid excess idling. Excessive idling causes carbon Operation and Maintenance Manual, “Diesel
buildup, engine slobber and, soot loading of the Particulate Filter - Clean” for more information on the
Diesel Particulate Filter (DPF). These issues are service of the DPF.
harmful to the engine.
Gauge readings should be observed and the data
Regeneration Indicators
should be recorded frequently whilst the engine is
operating. Comparing the data over time will help to Regeneration Active – When
determine normal readings for each gauge. illuminated, this indicator shows that
Comparing data over time will also help detect the system is active. This indicator
abnormal operating developments. Significant shows that elevated emission temperatures are
changes in the readings should be investigated. possible. This indicator will turn off when
regeneration is complete.
Engine Operation and the DPF – This indicator will illuminate to
Aftertreatment System show that regeneration is required. This
indicator will illuminate when “ Time to
The exhaust gases and hydrocarbon particles from Regen”” is less than a pre-determined amount of
the engine first pass through the Diesel Oxidation time.
Catalyst (DOC). Some of the gases and hydrocarbon
particles are oxidized as they pass through the DOC. Regeneration Disabled – This indicator
The gases then pass through the Diesel Particulate will illuminate to show that regeneration
Filter (DPF). The DPF collects the soot and any ash has been disabled.
that is produced by the combustion in the engine.
During regeneration, the soot is converted into a gas Regeneration Switch
and the ash remains in the DPF. The gases finally
pass through the Selective Catalytic Reduction
(SCR). Before the gases pass through the SCR, Force Regeneration – Press in the top
Diesel Exhaust Fluid (DEF) is injected into the gas switch for 2 seconds to begin
stream. The DEF is controlled by the Pump regeneration.
Electronic Unit (PEU). The mixtures of DEF and the
exhaust gas pass through the SCR reducing the NOx Disable Regeneration – Press in the
in the exhaust emissions. bottom switch for 2 seconds to disable
regeneration.
The engine software will control the amount of DEF
that will be required to keep the exhaust emission Note: If equipped with a rocker style switch, the
compliant. MIDDLE position of the regeneration switch is the
default position for automatic regeneration.
52 M0068760-05
Operation Section
Diesel Particulate Filter Regeneration

Note: If the engine start switch key is cycled or the Disabled: When the regeneration system is in
“Force Regeneration” switch is pressed for longer disabled mode, automatic regenerations will not be
than 2 seconds the system will no longer be disabled. performed. The DPF indicator will illuminate if manual
When the “Force Regeneration” switch is pressed regeneration is required. The “Time to Regen”
and “Time to Regen” is less than 8 hours, displayed on the performance screen will indicate
regeneration will begin if the machine is at low idle that the time until the next regeneration will be
and is parked. required. However, the DPF indicator may illuminate
with time remaining on the display. When the DPF
Note: If the engine start switch key is cycled whilst indicator illuminates, the operator must perform
the regeneration system is disabled via the “Disable manual regeneration.
Regeneration” switch, press and hold the “Disable
Regeneration” switch for 2 seconds to reinitiate. Regeneration Triggers
Modes of Regeneration Regeneration may be required for the following
reasons:
Automatic: The Electronic Control Module (ECM) Soot: The DPF will collect soot produced by the
uses multiple inputs from the engine and the machine engine. Automatic regeneration will become active to
to determine the best time to perform automatic reduce soot level.
regeneration. Automatic regenerations can take
place throughout the operating cycle of the engine. Start-Up Regeneration: Start-up regeneration is
The regeneration active indicator will be illuminated initiated by the ECM after a cold engine start. This
when regeneration is being performed. Interruptions regeneration is performed to heat the system to a
of the regeneration are acceptable. If regeneration is required temperature for Diesel Exhaust Fluid (DEF)
in progress and the regeneration needs to be dosing to begin.
stopped, it is permissible to press the “Disable
Regeneration” switch. SCR Maintenance: Regeneration is performed to
maintain the SCR system.
Note: Automatic adjustments of engine speed may
be noticed during regenerations. If regeneration is ARD Maintenance: Regeneration is performed to
maintain the CRS system.
taking place and the engine is taken to low idle, the
engine speed may remain elevated to maintain the
regeneration. Regeneration System Warning
Note: If the machine returns to work whilst automatic
Indicators
regeneration is active, the regeneration may be
stopped. The ECM will continue to monitor inputs to
determine the best time to restart the regeneration.
Manual: Manual regeneration is initiated by pressing
the “Force Regeneration” switch. Manual
regeneration will only be allowed if the “Time to
Regen” is less than 8 hours. If the “Force
Regeneration” switch is pressed before “Time to
Regen” is less than 8 hours, then “Regen not Illustration 52 g02117258
Required” will be displayed. The machine must be
stationary, the parking brake must be applied, and The DPF Indicator will illuminate solid when
the engine must be at low idle to perform manual regeneration is required. Regeneration should be
regeneration. performed as soon as possible.

Note: In some situations, the DPF indicator may stay

illuminated after regeneration ends. The illuminated
DPF indicator indicates that complete regeneration
has not been performed. Complete regeneration is
when the soot has been depleted or all the criteria for
one of the other regeneration types have been met. If
the DPF indicator stays illuminated, perform,
regeneration without interruption. The DPF indicator
will shut off when regeneration is complete.
M0068760-05 53
Operation Section
Engaging the Driven Equipment

If the soot load is above a threshold or “Time to

Regen” is 0 hours, then regeneration is required. The NOTICE
DPF indicator will illuminate and flash slowly. Engine The engine and emissions control system shall be
power will be slightly derated. If the machine operated, used, and maintained in accordance with
continues to operate without regeneration, derate will the instructions provided. Failure to follow the instruc-
eventually reach 100%. Stop the machine and apply tions could result in emissions performance that does
the parking brake. With the engine at low idle, initiate not meet the requirements applicable to the category
manual regeneration. of the engine. No deliberate tampering with, or mis-
use of the engine emissions control system should
take place. Prompt action is critical to rectify any in-
correct operation, use, or maintenance of the emis-
sions control system.

Carbon Dioxide (CO2) Emissions

Statement
Illustration 53 g03679876
Emissions regulations require that the value of the
Once the amount of soot collected in the DPF has CO2 emissions be reported to the end user. For this
reached a threshold or “Time to Regen” has been at engine, 760 g/kWh, (or 703 g/kWh for engine ratings
0 hours for a pre-determined time, the DPF indicator above 560kW (750hp) was determined to be the CO2
will illuminate and flash at a fast rate. A red stop lamp value during the EU type approval process. This
will illuminate solid. value was recorded in EU type approval certificate.
This CO2 measurement results from testing over a
10 minutes after the illumination of the DPF indicator fixed test cycle, under laboratory conditions, with a
and red stop lamp the engine will Shut down. The parent engine representative of the engine family.
engine can be restarted by cycling the engine start This value shall not imply or express any guarantee
switch key. The engine will return to the previous of the performance of a particular engine.
derate state before shutdown.
Once the amount of soot collected reaches a i04038637
threshold level or 6.4 hours of run time has passed
since the red stop lamp was illuminated without Engaging the Driven
successful regeneration, the engine will have a 100%
derate. Equipment
Once the amount of soot collected reaches a critical
threshold level, the regeneration will be locked out.
Now, regeneration can only be performed by 1. Operate the engine at one-half of the rated rpm,
usingelectronic service tool (ET). The engine may be when possible.
restarted, but will only run for 3 minutes before
shutting down again. 2. Engage the driven equipment without a load on the
equipment, when possible.
A fault code will be active for any DPF system-related
issue. Follow the troubleshooting guide to rectify the Interrupted starts put excessive stress on the drive
issue. train. Interrupted starts also waste fuel. To get the
driven equipment in motion, engage the clutch
If the DPF loses function, or is tampered with in any
way, the check engine lamp, and an amber action (if smoothly with no load on the equipment. This
equipped) will illuminate. A fault code will also method should produce a start that is smooth and
annunciate. The lamps and fault code will remain easy. The engine rpm should not increase and the
active until the problem is rectified. clutch should not slip.
3. Ensure that the ranges of the gauges are normal
when the engine is operating at one-half of the
rated rpm. Ensure that all gauges operate
properly.
4. Increase the engine rpm to the rated rpm. Always
increase the engine rpm to the rated rpm before
the load is applied.
54 M0068760-05
Operation Section
Fuel Conservation Practices

5. Apply the load. Begin operating the engine at low • Ensure that the driven equipment is in good
load. Check the gauges and equipment for proper working order.
operation. After normal oil pressure is reached and
the temperature gauge begins to move, the engine • Cold engines consume excess fuel. Utilize heat
from the jacket water system and the exhaust
may be operated at full load. Check the gauges
system, when possible. Keep cooling system
and equipment frequently when the engine is components clean and keep cooling system
operated under load. components in good repair. Never operate the
Extended operation at low idle or at reduced load engine without water temperature regulators. All
these items will help maintain operating
may cause increased oil consumption and carbon
temperatures.
buildup in the cylinders. This carbon buildup
results in a loss of power and/or poor
performance.

i07677865

Fuel Conservation Practices

The efficiency of the engine can affect the fuel

economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
to attain optimum performance for the life of the
engine.
• Avoid spilling fuel.
Fuel expands when it is warmed up. The fuel may
overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
• Be aware of the properties of different fuels. Use
only the recommended fuels. Refer to the
Operations and Maintenance Manual, “Fuel
Recommendations” for further information.
• Avoid unnecessary idling.
Shut off the engine rather than allowing the engine to
idle for long periods of time.
• Observe the service indicator frequently. Keep the
air cleaner elements clean.

• Ensure that the turbocharger is operating

correctly. For more information refer to this
Operation and Maintenance Manual,
“Turbocharger - Inspect”
• Maintain a good electrical system.
One faulty battery cell will overwork the alternator.
This fault will consume excess power and excess
fuel.
• The belt should be in good condition. Refer to the
Systems Operation, Testing and Adjusting, “V-Belt
Test” for further information.
• Ensure that all the connections of the hoses are
tight. The connections should not leak.
M0068760-05 55
Operation Section
Engine Stopping

Engine Stopping
Leaving the machine unattended when the engine
i05798719
is running may result in personal injury or death.
Before leaving the machine operator station, neu-
Stopping the Engine tralize the travel controls, lower the work tools to
the ground and deactivate all work tools, and
place the lever for the hydraulic lockout control
in the LOCKED position.
NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac- Note: Leaving the engine unattended while running
celerated wear of the engine components. may result in property damage in the event of a
malfunction.
See the following stopping procedure, to allow the
engine to cool, and to prevent excessive tempera- Turn the engine start switch to the OFF position.
tures in the turbocharger center housing, which could
cause oil coking problems. Delayed Engine Shutdown – The
delayed engine shutdown indicator will
illuminate or the following text will be
1. While the machine is stopped, run the engine for 5 displayed, ENGINE COOLDOWN ACTIVE.
minutes at low idle. Idling the engine allows hot
areas of the engine to cool gradually. Delayed engine shutdown will run whenever the
exhaust temperature is above a threshold at engine
Note: If the “Regen Active” indicator is illuminated, shutdown. Delayed engine shutdown will run for a
do not shut off the engine. Refer to Operation and minimum of 76 seconds and will continue to run until
Maintenance Manual, “Monitoring System” for more the engine and system components are cooled. The
information on indicators. (if equipped) default maximum run time is 7 minutes.

2. Turn the engine start switch to the OFF position Note: An authorized dealer can change the
maximum run time value up to 30 minutes, but the
and remove the key.
default setting is 7 minutes.
Note: The engine may delay before completely
Note: To override delayed engine shutdown and stop
shutting down. Delayed engine shutdowns aid in
the engine, turn the engine start switch to the STOP
cooling the engine and after-treatment (if equipped)
position. Overriding delayed engine shutdown may
components.
reduce engine and system component life. A warning
message and/or audible alarm will be initiated and a
Delayed Engine Shutdown (If fault code will be logged for improper engine
Enabled) shutdown.

The Delayed Engine Shutdown allows the engine to

run for a time after the engine start switch key is
turned to the OFF position to cool the engine and
system components. The engine start switch key
may be removed.

Note: The DEF purge process will run for 2 minutes

once the engine is shut down and must complete.
The purge process may occur during delayed engine
shutdown. Do not turn off battery disconnect switch
during the purge process. Do not turn off the battery
power disconnect switch until the battery disconnect
switch indicator lamp has turned off. If the purge
process does not complete, a diagnostic code will
become active.
Note: There may be regulations that define the
requirements for the operator and/or support
personnel to be present when the engine is running.
56 M0068760-05
Operation Section
Manual Stop Procedure

i01465494

After Stopping Engine

Note: Before you check the engine oil, do not

operate the engine for at least 10 minutes in order to
allow the engine oil to return to the oil pan.

• Check the crankcase oil level. Maintain the oil

level between the “ADD” mark and the “FULL”
mark on the oil level gauge.

• If necessary, perform minor adjustments. Repair

any leaks and tighten any loose bolts.
Illustration 54 g02362719
• Note the service hour meter reading. Perform the
Note: At any time during a delayed engine shutdown, maintenance that is in the Operation and
the engine start switch may be turned to the ON Maintenance Manual, “Maintenance Interval
position. The engine may be placed back into Schedule”.
service.
• Fill the fuel tank in order to help prevent
i05812522 accumulation of moisture in the fuel. Do not overfill
the fuel tank.
Manual Stop Procedure
NOTICE
Only use antifreeze/coolant mixtures recommended
in the Coolant Specifications that are in the Operation
NOTICE and Maintenance Manual. Failure to do so can cause
Stopping the engine immediately after it has been engine damage.
working under load can result in overheating and ac-
celerated wear of the engine components.
• Allow the engine to cool. Check the coolant level.
If the engine has been operating at high rpm and/or
high loads, run at low idle for at least three minutes to • If freezing temperatures are expected, check the
reduce and stabilize internal engine temperature be- coolant for proper antifreeze protection. The
fore stopping the engine. cooling system must be protected against freezing
to the lowest expected outside temperature. Add
Avoiding hot engine shutdowns will maximize turbo- the proper coolant/water mixture, if necessary.
charger shaft and bearing life.
• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
Note: Individual applications have different control the instructions from the OEM.
systems. Ensure that the shutoff procedures are
understood. Use the following general guidelines in
order to stop the engine.

1. Remove the load from the engine so that the

engine has no more than 30% power.
2. Run the engine at the programmed low idle speed
for at least 3 minutes.
3. After the cool down period, turn the start switch to
the OFF position.
M0068760-05 57
Operation Section
Cold Weather Operation

Cold Weather Operation • Install the correct specification of engine lubricant

before the beginning of cold weather. Refer to this
Operation and Maintenance Manual, “Fluid
i07003037 Recommendations” for the recommended
viscosity of oil.
Cold Weather Operation
• Check all rubber parts (hoses, fan drive belts)
weekly.
Perkins Diesel Engines can operate effectively in
cold weather. During cold weather, the starting and • Check all electrical wiring and connections for any
the operation of the diesel engine depends on the fraying or damaged insulation.
following items:
• Keep all batteries fully charged and warm by
• The type of fuel that is used ensuring that the engine is allowed to operate at
normal operating temperature.
• The viscosity of the engine oil
• Fill the fuel tank at the end of each shift.
• Cold starting aid
• Check the air cleaners and the air intake daily.
• Battery condition Check the air intake more often when you operate
in snow.
• Ambient air temperature and altitude
• If equipped, ensure that the cold weather starting
• Parasitic load of the application aid is operating correctly
• Application hydraulic and transmission oil • For jump starting with cables in cold weather, refer
viscosities to the Operation and Maintenance Manual,
“Starting with Jump-Start Cables.” for instructions.
This section will cover the following information:
• Potential problems that are caused by cold- Viscosity of the Engine Lubrication
weather operation Oil
• Suggest steps which can be taken to minimize Correct engine oil viscosity is essential. Oil viscosity
starting problems and operating problems when affects lubrication properties and wear protection that
the ambient air temperature is between the oil provides for the engine. Refer to this Operation
0° to−40 °C (32° to 40 °F). and Maintenance Manual, “Fluid Recommendations”
for the recommended viscosity of oil.
The operation and maintenance of an engine in
freezing temperatures is complex . This complexity is At temperatures below −10° C (14° F) damage to
because of the following conditions: engine components can occur if the engine is
allowed to operate at high load and speed
• Weather conditions immediately after starting.
• Engine applications
Recommendations for the Coolant
Recommendations from your Perkins distributor are
based on past proven practices. The information that Provide cooling system protection for the lowest
is contained in this section provides guidelines for expected outside temperature. Refer to this
cold-weather operation. Operation and Maintenance Manual, “Fluid
Recommendations” for the recommended coolant
mixture.
Hints for Cold-Weather Operation
In cold weather, check the coolant often for the
• Achieving operating temperature will help prevent correct glycol concentration to ensure adequate
freeze protection.
the intake valves and exhaust valves from
sticking.
Engine Block Heaters
• The cooling system and the lubrication system for
the engine do not lose heat immediately upon Engine block heaters (if equipped) heat the engine
shutdown. An engine can be shut down for a jacket water that surrounds the combustion
period and the retained heat within the engine will chambers. This heat provides the following functions:
allow the engine readily start.
• Startability is improved.

• Warm up time is reduced.

58 M0068760-05
Operation Section
Radiator Restrictions

An electric block heater can be activated once the • Valves become stuck.
engine is stopped. A block heater can be 110 V dc or
240 V dc. Consult your Perkins distributor for more • Pushrods may become bent.
information.
• Other damage to valve train components can
Extended Idle at Cold Ambient result.
Temperature For these reasons, when the engine is started, the
engine must be operated until the coolant
The engine may automatically change speeds when temperature is 80° C (176° F) minimum. Carbon
the engine is idling in cold ambient temperatures deposits on the valve stem will be kept at a minimum.
(typically less than 0° C (32° F) for extended periods. The free operation of the valves and the valve
The purpose of the automatic speed change is components will be maintained.
threefold: To maintain the desired operation of the
NOx reduction system, to maintain the desired The engine must be warmed thoroughly to keep
operation of the regeneration system and to keep the other engine parts in better condition. The service life
engine coolant warm. The engine speed may rise to of the engine will be generally extended. Lubrication
1600 rpm for as long as 20 minutes. will be improved. There will be less acid and less
sludge in the oil. This condition will provide longer
The high exhaust system temperature lamp may service life for the engine bearings, the piston rings,
illuminate during extended idling conditions. This and other parts. However, limit unnecessary idle time
illumination signals that a diesel particulate filter to 10 minutes to reduce wear and unnecessary fuel
(DPF) regeneration is in progress. Regenerations consumption.
during cold ambient extended idling may only last up
to 10 minutes. Insulated Heater Lines
Idling the Engine A cab heater is beneficial in cold weather. The feed
from the engine and the return lines from the cab
should be insulated to reduce heat loss to the outside
The engine should not be “raced” to speed up the air.
warm-up process.
i07622821
While the engine is idling, the application of a light
load (parasitic load) will help in achieving the
minimum operating temperature. The minimum Radiator Restrictions
operating temperature is 80° C (176° F).

Recommendations for Coolant Perkins discourages the use of airflow restriction

devices that are mounted in front of radiators. Airflow
Warm Up restriction can cause the following conditions:
Warm up an engine that has cooled below normal • High exhaust temperatures
operating temperatures due to inactivity. This warm
-up should be performed before the engine is • Power loss
returned to full operation. During operation in very
cold temperature conditions, damage to engine valve • Excessive fan usage
mechanisms can result from engine operation for
short intervals. This damage can happen if the • Reduction in fuel economy
engine is started and the engine is stopped many
times without being operated to warm-up completely. Reducing air flow over components will also affect
under hood temperatures. Reducing air flow can
When the engine is operated below normal operating increase surface temperatures during an
temperatures, fuel and oil are not burned completely aftertreatment regeneration and could affect
in the combustion chamber. This fuel and oil causes component reliability.
soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and If an airflow restriction device must be used, the
the deposits are burned off during operation at device should have a permanent opening directly in
normal engine operating temperatures. line with the fan hub. The device must have a
minimum opening dimension of at least 770 cm2
When starting and stopping an engine many times (120 in2).
without being operated to warm-up completely, the
carbon deposits become thicker. This starting and A centered opening that is directly in line with the fan
stopping can cause the following problems: hub is specified to prevent an interrupted airflow on
the fan blades. Interrupted airflow on the fan blades
• Free operation of the valves is prevented. could cause a fan failure.
M0068760-05 59
Operation Section
Fuel and the Effect from Cold Weather

Perkins recommends a warning device for the inlet Winter and arctic grades of diesel fuel are available in
manifold temperature and/or the installation of an the countries and territories with severe winters. For
inlet air temperature gauge. The warning device for more information refer to the Operation and
the inlet manifold temperature should be set at 75 °C Maintenance Manual, “Fuel For Cold Weather
(167 °F). The inlet manifold air temperature should Operation”
not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential Another important fuel property which can affect cold
engine damage. start and operation of diesel engine is Cetane
number. Detail and requirements of this property are
given in this Operation and Maintenance Manual,
i05849931 “Fluid Recommendations”.
Fuel and the Effect from Cold i06093465
Weather
Fuel Related Components in
Cold Weather
Note: Only use grades of fuel that are recommended
by Perkins. Refer to this Operation and Maintenance
Manual, “Fluid Recommendations”.
Fuel Tanks
Properties of the diesel fuel can have a significant
effect on the engine cold start capability. It is critical Condensation can form in partially filled fuel tanks.
that the low temperature properties of diesel fuel are Top off the fuel tanks after operating the engine.
acceptable for the minimum ambient temperature the
engine is expected to see in the operation. Fuel tanks should contain some provision for draining
water and sediment from the bottom of the tanks.
Following properties are used to define fuels low Some fuel tanks use supply pipes that allow water
temperature capability: and sediment to settle below the end of the fuel
supply pipe.
• Cloud point
Some fuel tanks use supply lines that take fuel
• Pour point directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
• Cold Filter Plugging Point (CFPP) the fuel system filter is important.

The cloud point of the fuel is the temperature at Drain the water and sediment from any fuel storage
which waxes naturally found in the diesel fuel begin tank at the following intervals:
to form crystals. The cloud point of the fuel must be
below lowest ambient temperature to prevent filters • Weekly
from plugging.
• Oil changes
Cold Filter Plugging Point is a temperature at which a
particular fuel will pass through a standardized • Refueling of the fuel tank
filtration device. This CFPP gives an estimate of the
lower operability temperature of fuel This draining will help prevent water and/or sediment
from being pumped from the fuel storage tank and
Pour point is the last temperature before the fuel flow into the engine fuel tank.
stops and waxing of the fuel will start.
Be aware of these properties when diesel fuel is
Fuel Heaters
purchased. Consider the average ambient air Fuel heaters help to prevent fuel filters from plugging
temperature for the engines application. Engines that in cold weather due to waxing. A fuel heater should
are fueled in one climate may not operate well if the be installed in order for the fuel to be heated before
engines are shipped to colder climate. Problems can the fuel enters the primary fuel filter.
result due to changes in temperature.
Select a fuel heater that is mechanically simple, yet
Before troubleshooting for low power or for poor adequate for the application. The fuel heater should
performance in the winter, check the fuel for waxing also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
The following components can provide a means of availability of engine power. Choose a fuel heater
minimizing fuel waxing problems in cold weather: with a large heating surface. The fuel heater should
be practical in size. Small heaters can be too hot due
• Fuel heaters, which may be an OEM option to the limited surface area.
• Fuel line insulation, which may be an OEM option Disconnect the fuel heater in warm weather.
60 M0068760-05
Operation Section
Fuel Related Components in Cold Weather

Note: Fuel heaters that are controlled by the water

temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters that are
not controlled by the water temperature regulator can
heat the fuel in excess of 65° C (149° F). A loss of
engine power can occur if the fuel supply
temperature exceeds 37° C (100° F).
Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
the fuel in warm-weather operation.
For further information on fuel heaters, consult your
Perkins distributor .
M0068760-05 61
Maintenance Section
Refill Capacities

Maintenance Section DEF Quality

The quality of DEF can be measured by using a

refractometer. The DEF must comply with ISO
Refill Capacities standard 22241-1 with the urea solution of 32.5
percent. Perkins offer a T400195 Refractometer for
checking the concentration of the DEF.
i07636462
Cleanliness
Fluid Recommendations
Contaminants can degrade the quality and life of
(Diesel Exhaust Fluid (DEF)) DEF. Filtering DEF is recommended when dispensed
into the DEF tank. Filters should be compatible with
DEF and should be used exclusively with DEF.
Check with the filter supplier to confirm compatibility
General Information with DEF before using. Mesh-type filters using
compatible metals, such as stainless steel, are
Diesel Exhaust Fluid (DEF) is a liquid that is injected recommended. Paper (cellulose) media and some
into the aftertreatment system before Selective synthetic filter media are not recommended because
Catalytic Reduction (SCR). This system of injecting of degradation during use.
the DEF into the exhaust will cause a chemical
reaction in the SCR system. The Nitrogen Oxide Care should be taken when dispensing DEF. Spills
(NOx) molecules in the exhaust are converted to should be cleaned immediately. Machine or engine
elemental nitrogen and water. This conversion will surfaces should be wiped clean and rinsed with
reduce the emission of the engine. water. Caution should be used when dispensing DEF
near an engine that has recently been running.
Specification Spilling DEF onto hot components will cause harmful
vapors.
DEF that is used in Perkins engines must meet the
ISO specification 22241-1 for quality. The ISO Storage
specification 22241-1 requirements are met by many
brands of DEF, including the ones that carry the Do not store DEF in direct sunlight.
AdBlue or API certification." Table 5

The document series ISO standard 22241 will give Storage Temperature Expected DEF Life
information on quality requirements, test methods, Below 25° C (77° F) 18 months
handling, transportation, storage, and refilling
interface. 25° C (77° F) to 30° C (86° F) 12 months

30° C (86° F) to 35° C (95° F) 6 months

Spillage
Above 35° C (95° F) test quality before use
Care should be taken when dispensing DEF. Spills
should be cleaned immediately. All surfaces should
be wiped clean and rinsed with water. Perkins recommend that all DEF taken from storage
should be checked to ensure that the DEF meets ISO
DEF that has been spilt will crystallize when the standard 22241-1.
water within the liquid evaporates. Spilt DEF will
attack paint and metal. If DEF is spilt, wash the area Materials compatibility
with water.
DEF is corrosive. Due to the corrosion caused, DEF
Caution should be used when dispensing DEF near must be stored in tanks constructed of approved
an engine that has recently been running. Spilling materials. Recommended storage materials:
DEF onto hot components may cause the release of
ammonia vapors. Do not breathe ammonia vapors. Stainless Steels:
Do not clean up any spills with bleach.
• 304 (S30400)
Filling the DEF Tank • 304L (S30403)
The fill cap on the DEF tank must be colored blue. • 316 (S31600)
The DEF level is important, allowing the DEF tank to
run dry or operate at a low level can affect the engine • 316L (S31603)
operation. Because of the corrosive nature of DEF,
the correct materials must be used when filling a DEF Alloys and metals:
tank.
• Chromium Nickel (CrNi)
62 M0068760-05
Maintenance Section
Fluid Recommendations

• Chromium Nickel Molybdenum (CrNiMo)

• Titanium
Non-metallic materials:
• Polyethylene
• Polypropylene

• Polyisobutylene
• Teflon (PFA)

• Polyfluoroethylene (PFE)
• Polyvinylidene fluoride (PVDF)
Illustration 55 g06183768

• Polytetrafluoroethylene (PTFE) Typical API symbol

Materials NOT compatible with DEF solutions include Terminology

Aluminum, Magnesium, Zinc, Nickel coatings, Silver,
and Carbon steel and Solders containing any of the
Certain abbreviations follow the nomenclature of
above. Unexpected reactions may occur if DEF “SAE J754”. Some classifications follow “SAE J183”
solutions come in contact with any non-compatible abbreviations, and some classifications follow the
material or unknown materials. “EMA Recommended Guideline on Diesel Engine
Oil”. In addition to Perkins definitions, there are other
i07754639 definitions that will be of assistance in purchasing
lubricants. Recommended oil viscosities can be
found in this publication, “Fluid Recommendations/
Fluid Recommendations Engine Oil” topic (Maintenance Section).

Engine Oil
General Lubricant Information
Commercial Oils
Because of government regulations regarding the
certification of exhaust emissions from the engine, Perkins recommends use of Perkins Diesel Engine
the lubricant recommendations must be followed. Oil for all Perkins engines. Perkins unique oil
formulations have been developed to provide full
• API American Petroleum Institute performance and maximum service life of your
engine, and in tests have been shown to provide
• SAE Society Of Automotive Engineers Inc. superior protection. Available in suitable API
classifications to meet the emissions requirements
• ACEA Association des Constructers and performance of your engine, Refer to 6 for the
European Automobiles. correct oil specification for your engine. Consult your
Perkins distributor for more information on these
• ECF-3 Engine Crankcase Fluid multi-grade oils.

Licensing NOTICE
Perkins require the use of the following specifica-
The Engine Oil Licensing and Certification System by tion of engine oil. Failure to use the appropriate
the American Petroleum Institute (API) and the specification of engine oil will reduce the life of
Association des Constructers European Automobiles your engine. Failure to use the appropriate speci-
and (ACRA) is recognized by Perkins. For detailed fication of engine oil will also reduce the life of
information about this system, see the latest edition your aftertreatment system.
of the “API publication No. 1509”. Engine oils that
bear the API symbol are authorized by API. Table 6
Oil Specification

API CK-4
ACEA E9
ECF-3
M0068760-05 63
Maintenance Section
Fluid Recommendations

API CK-4 and ACEA E9 oil categories have the Generally, use the highest oil viscosity that is
following chemical limits: available to meet the requirement for the temperature
at start-up.
• 0.1 percent maximum sulfated ash
• 0.12 percent maximum phosphorous

• 0. 4 percent maximum sulfur

The chemical limits were developed to maintain the
expected life of the engine aftertreatment system.
The performance of the engine aftertreatment system
can be adversely affected if oil that is not specified in
table 6 is used.
The life of your Aftertreatment system is defined by
the accumulation of ash on the surface of the filter.
Ash is the inert part of the particulate matter. The
system is designed to collect this particulate matter.
There is a small percentage of particulate matter that
is left behind as the soot is burnt. This matter will
eventually block the filter, causing loss of
performance and increased fuel consumption. Most
of the ash comes from the engine oil which is
gradually consumed during normal operation. This
ash is passes through the exhaust. To meet the
designed life of the product, the use of the
appropriate engine oil is essential. The oil Illustration 56 g03329707
specification that is listed in table 6 has low ash Lubricant Viscosities
content. Supplemental heat is recommended for cold soaked
Maintenance intervals for engines that use starts below the minimum ambient temperature.
biodiesel – The oil change interval can be adversely Supplemental heat may be required for cold soaked
affected by the use of biodiesel. Use oil analysis to starts that are above the minimum temperature that
monitor the condition of the engine oil. Use oil is stated, depending on the parasitic load and other
analysis also to determine the oil change interval that factors. Cold soaked starts occur when the engine
is optimum. has not been operated for a period of time. This
interval will allow the oil to become more viscous due
to cooler ambient temperatures.
Note: API FA-4 oil is designed for use in selected
on-highway applications and is NOT designed to Aftermarket Oil Additives
support off-road applications, including Perkins
Engines. DO NOT use API FA-4 oil for Perkins Perkins does not recommend the use of aftermarket
engines. These engine oils are not approved by additives in oil. Aftermarket additives are not
necessary to achieve the engines maximum service
Perkins and these engine oils must not be used: life or rated performance. Fully formulated, finished
CC, CD, CD-2, CF-4, CG-4, CH-4, and CI-4. oils consist of base oils and of commercial additive
packages. These additive packages are blended into
Lubricant Viscosity Recommendations the base oils at precise percentages to help provide
for Direct Injection (DI) Diesel Engines finished oils with performance characteristics that
meet industry standards.
The correct SAE viscosity grade of oil is determined There are no industry standard tests that evaluate
by the minimum ambient temperature during cold the performance or the compatibility of aftermarket
engine start-up, and the maximum ambient additives in finished oil. Aftermarket additives may
temperature during engine operation. not be compatible with the finished oils additive
Refer to illustration 56 (minimum temperature) to package, which could lower the performance of the
determine the required oil viscosity for starting a cold finished oil. The aftermarket additive could fail to mix
with the finished oil. This failure could produce sludge
engine. in the crankcase. Perkins discourages the use of
Refer to illustration 56 (maximum temperature) to aftermarket additives in finished oils.
select the oil viscosity for engine operation at the To achieve the best performance from a Perkins
highest ambient temperature that is anticipated. engine, conform to the following guidelines:
64 M0068760-05
Maintenance Section
Fluid Recommendations

• See the appropriate “Lubricant Viscosities” . Refer

NOTICE
to the illustration 56 to find the correct oil viscosity If the engine is to be stored in, or shipped to an area
grade for your engine. with below freezing temperatures, the cooling system
must be either protected to the lowest outside tem-
• At the specified interval, service the engine. Use perature or drained completely to prevent damage.
new oil and install a new oil filter.

• Perform maintenance at the intervals that are

specified in the Operation and Maintenance NOTICE
Frequently check the specific gravity of the coolant
Manual, “Maintenance Interval Schedule”. for proper freeze protection or for anti-boil protection.
Oil analysis Clean the cooling system for the following reasons:

Some engines may be equipped with an oil sampling • Contamination of the cooling system
valve. If oil analysis is required, the oil sampling valve
is used to obtain samples of the engine oil. The oil • Overheating of the engine
analysis will complement the preventive maintenance
program. • Foaming of the coolant
The oil analysis is a diagnostic tool that is used to
determine oil performance and component wear NOTICE
Never operate an engine without water temperature
rates. Contamination can be identified and measured regulators in the cooling system. Water temperature
by using oil analysis. The oil analysis includes the
following tests: regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
• The Wear Rate Analysis monitors the wear of the lems can develop without water temperature
engines metals. The amount of wear metal and regulators.
type of wear metal that is in the oil is analyzed.
The increase in the rate of engine wear metal in Many engine failures are related to the cooling
the oil is as important as the quantity of engine system. The following problems are related to cooling
wear metal in the oil. system failures: Overheating, leakage of the water
pump and plugged radiators or heat exchangers.
• Tests are conducted to detect contamination of the
oil by water, glycol, or fuel. These failures can be avoided with correct cooling
system maintenance. Cooling system maintenance is
• The Oil Condition Analysis determines the loss of as important as maintenance of the fuel system and
the oils lubricating properties. An infrared analysis the lubrication system. Quality of the coolant is as
is used to compare the properties of new oil to the important as the quality of the fuel and the lubricating
properties of the used oil sample. This analysis oil.
allows technicians to determine the amount of
Coolant is normally composed of three elements:
deterioration of the oil during use. This analysis Water, additives, and glycol.
also allows technicians to verify the performance
of the oil according to the specification during the
entire oil change interval.
Water
Water is used in the cooling system to transfer heat.
i07835621
Note: The water must be used with an inhibitor to
Fluid Recommendations protect the engine.
Distilled water or deionized water is
recommended for use in engine cooling systems.
DO NOT use the following types of water in cooling
systems: Hard water, softened water that has been
General Coolant Information conditioned with salt and sea water.
If distilled water or deionized water is not available,
NOTICE use water with the properties that are listed in Table 7
Never add coolant to an overheated engine. Engine .
damage could result. Allow the engine to cool first.
M0068760-05 65
Maintenance Section
Fluid Recommendations

Table 7
Acceptable Water • Cavitation of the water pump
Property Maximum Limit For optimum performance, Perkins recommends a
Chloride (Cl) 40 mg/L 50 percent by volume of glycol in the finished coolant
(also referred to as 1:1 mixture).
Sulfate (SO4) 100 mg/L
Note: Use a mixture that will provide protection
Total Hardness 170 mg/L against the lowest ambient temperature.
Total Solids 340 mg/L
Note: 100 percent pure glycol will freeze at a
Acidity pH of 5.5 to 9.0 temperature of −13 °C (8.6 °F).
Most conventional antifreezes use ethylene glycol.
For a water analysis, consult one of the following Propylene glycol may also be used. In a 1:1 mixture
sources: with water, ethylene and propylene glycol provide
similar protection against freezing and boiling. Refer
• Local water utility company to Table 8 and refer to table 9 .
Table 8
• Agricultural agent
Ethylene Glycol
• Independent laboratory
Concentration Freeze Protection
Additives 50 Percent −36 °C (−33 °F)

Additives help to protect the metal surfaces of the 60 Percent −51 °C (−60 °F)
cooling system. A lack of coolant additives or
insufficient amounts of additives enable the following
conditions to occur: NOTICE
Do not use propylene glycol in concentrations that
• Corrosion exceed 50 percent glycol because of the reduced
heat transfer capability of propylene glycol. Use ethyl-
• Formation of mineral deposits ene glycol in conditions that require additional protec-
tion against boiling or freezing.
• Rust
Table 9
• Scale
Propylene Glycol
• Foaming of the coolant
Concentration Freeze Protection
Many additives are depleted during engine operation.
These additives must be replaced periodically. 50 Percent −29 °C (−20 °F)

Additives must be added at the correct concentration. To check the concentration of glycol in the coolant,
Over concentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can measure the specific gravity of the coolant.
enable the following problems to occur:
Note: Some commercially available coolants are
• Formation of gel compounds based on alternative fluids, such as 1, 3-propanediol
(beta-propylene glycol, PDO), glycerin (glycerol), or
• Reduction of heat transfer mixtures of these alternatives with ethylene/
propylene glycols. At the time of publication of this
• Leakage of the water pump seal document no industry standard exists for coolants
based on these chemicals. Until such standard/
• Plugging of radiators, coolers, and small passages specifications are published and evaluated by
Perkins, use of PDO, glycerine, or other alternative
Glycol coolants are not recommended in Perkins diesel
engines.
Glycol in the coolant helps to provide protection
against the following conditions: Coolant Recommendations
• Boiling
• ELC Extended Life Coolant
• Freezing
• SCA Supplement Coolant Additive
66 M0068760-05
Maintenance Section
Fluid Recommendations

• ASTM American Society for Testing and Perkins recommends a 50% mixture of water and
Materials glycol. This mixture of water and glycol will provide
optimum heavy-duty performance as an antifreeze.
ELC - extended life coolant. A coolant that relies on This ratio may be changed to 40% water to 60%
organic inhibitors for corrosion and cavitation glycol if extra freezing protection is required.
protection. Also called OAT coolant (Organic Acid
Technology). A mixture of SCA inhibitor and water is acceptable
but will not give as much corrosion, boiling and,
SCA - supplemental coolant additive, concentrated freezing protection as ELC. Perkins recommends a 6
inorganic inhibitor package. percent to 8 percent concentration of SCA in those
cooling systems. Distilled water or deionized water is
Extender - concentrated organic inhibitor package. preferred.
Conventional Coolant - a coolant that relies on Table 10
inorganic inhibitors for corrosion and cavitation Coolant Service Life
protection.
Coolant Type Service Life (1)
Hybrid Coolant - a coolant in which the corrosion and
cavitation protection is based on a mixture of organic 6,000 Service Hours or Three
Perkins ELC
and inorganic inhibitors. Years
Commercial Heavy-Duty Anti-
The following coolants are recommended for used in freeze that meets “ASTM 3000 Service Hours or Two Year
Perkins diesel engines: D6210”

Preferred – Perkins ELC Commercial SCA inhibitor and

3000 Service Hours or One Year
Water
(1) Use the interval that occurs first. The cooling system must also
Acceptable – A commercial heavy-duty antifreeze
be flushed out at this time.
that meets “ASTM D6210” or “ASTM D4985”
specifications.
Perkins ELC
NOTICE Perkins provides ELC for use in the following
The Perkins industrial engines with a NOx reduc- applications:
tion system must be operated with a minimum
30% volume glycol-water mixture, Perkins recom- • Heavy-duty spark ignited gas engines
mends 50% volume glycol-water mixture of water
and glycol. The 50% concentration allows the • Heavy-duty diesel engines
NOx reduction system to operate correctly at
high ambient temperatures. • Automotive applications
The anti-corrosion package for ELC is different from
the anti-corrosion package for other coolants. ELC is
NOTICE an ethylene glycol base coolant. However, ELC
Do not use a commercial coolant/antifreeze that only
meets the ASTM D3306 specification. This type of contains organic corrosion inhibitors and antifoam
coolant/antifreeze is made for light automotive agents with low amounts of nitrite. Perkins ELC has
applications. been formulated with the correct amount of these
additives to provide superior corrosion protection for
all metals in engine cooling systems.
NOTICE ELC is available in a premixed cooling solution with
A commercial heavy-duty antifreeze that meets distilled water. ELC is a 50 percent by volume of
“ASTM D4985” specification requires a treatment glycol mixture. The Premixed ELC provides freeze
with an SCA at the initial fill. Read the label or the in- protection to −36 °C (−33 °F). The Premixed ELC is
structions that are provided by the manufacturer of recommended for the initial fill of the cooling system.
the product. The Premixed ELC is also recommended for topping
off the cooling system.

NOTICE
A commercial heavy-duty antifreeze that meets either
“ASTM D4985” or “ASTM D6210” specification re-
quires the SCA concentration to be checked at 500-
hour service intervals.
M0068760-05 67
Maintenance Section
Fluid Recommendations

Containers of several sizes are available. Consult

your Perkins distributor for the part numbers. NOTICE
Care must be taken to ensure that all fluids are con-
tained during performance of inspection, mainte-
ELC Cooling System Maintenance nance, testing, adjusting and the repair of the
product. Be prepared to collect the fluid with suitable
Correct additions to the Extended Life containers before opening any compartment or disas-
sembling any component containing fluids.
Coolant
Dispose of all fluids according to local regulations
and mandates.
NOTICE
Use only Perkins products for pre-mixed coolants.
1. Drain the coolant into a suitable container.
Mixing Extended Life Coolant with other products re-
duces the Extended Life Coolant service life. Failure 2. Dispose of the coolant according to local
to follow the recommendations can reduce cooling
regulations.
system components life unless appropriate corrective
action is performed. 3. Fill the cooling system with a 33 percent solution of
Perkins ELC and operate the engine, ensure that
To maintain the correct balance between the
antifreeze and the additives, you must maintain the the thermostat opens. Stop the engine and allow
recommended concentration of ELC. Lowering the the engine to cool. Drain the coolant.
proportion of antifreeze lowers the proportion of
additive. Lowering the ability of the coolant to protect Note: Use distilled or deionized water in the solution.
the system will form pitting, from cavitation, from
erosion, and from deposits. 4. Again, fill the cooling system with a 33 percent
solution of Perkins ELC and operate the engine
NOTICE ensure that the thermostat opens. Stop the engine
Do not use a conventional coolant to top-off a cooling and allow to cool.
system that is filled with Extended Life Coolant
(ELC). 5. Drain the cooling system.
Do not use supplemental coolant additive (SCA). NOTICE
Incorrect or incomplete flushing of the cooling system
can result in damage to copper and other metal
ELC Cooling System Cleaning components.

Note: If the cooling system is already using ELC,

cleaning agents are not required to be used at the NOTICE
specified coolant change interval. Cleaning agents Most commercial cooling system cleaning agents are
are only required if the system has been corrosive and their use is not recommended by
contaminated by the addition of some other type of Perkins.
coolant or by cooling system damage.
Clean water is the only cleaning agent that is 6. Fill the cooling system with the Perkins Premixed
required when ELC is drained from the cooling ELC. Operate the engine. Ensure that all coolant
system. valves open then stop the engine. When cool
check the coolant level.
Before the cooling system is filled, the heater control
(if equipped) must be set to the HOT position. Refer ELC Cooling System Contamination
to the OEM to set the heater control. After the cooling
system is drained and the cooling system is refilled,
operate the engine until the coolant level reaches the NOTICE
normal operating temperature and until the coolant Mixing ELC with other products reduces the effective-
level stabilizes. As needed, add the coolant mixture ness of the ELC and shortens the ELC service life.
to fill the system to the specified level. Failure to follow these recommendations can result in
shortened cooling system component life.
Changing to Perkins ELC ELC cooling systems can withstand contamination to
a maximum of 10 percent of conventional heavy-duty
To change from heavy-duty antifreeze to the Perkins antifreeze or SCA. If the contamination exceeds 10
ELC, perform the following steps: percent of the total system capacity, perform ONE of
the following procedures:
68 M0068760-05
Maintenance Section
Fluid Recommendations

• Drain the cooling system into a suitable container. Table 11

Dispose of the coolant according to local Equation For Adding The SCA To The Heavy-Duty Coolant At
regulations. Flush the system with a 5 to 10 The Initial Fill
percent solution of Perkins ELC. Fill the system
with the Perkins ELC. V × 0.07 = X
V is the total volume of the cooling system.
• Maintain the system as a conventional Heavy-
Duty Coolant. Treat the system with an SCA. X is the amount of SCA that is required.
Change the coolant at the interval that is
recommended for the conventional Heavy-Duty Table 12 is an example for using the equation that is
Coolant. in Table 11 .
Table 12
Commercial Heavy-Duty Antifreeze and
Example Of The Equation For Adding The SCA To The Heavy-
SCA Duty Coolant At The Initial Fill

Total Volume of the Multiplication Amount of SCA

NOTICE Cooling System (V) Factor that is Required
Commercial Heavy-Duty Coolant which contains (X)
Amines as part of the corrosion protection system
must not be used. 15 L (4 US gal) × 0.07 1.05 L (35.5 oz)

NOTICE Adding The SCA to The Heavy-Duty

Never operate an engine without water temperature Coolant For Maintenance
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the Heavy-duty antifreeze of all types REQUIRE periodic
correct operating temperature. Cooling system prob- additions of an SCA.
lems can develop without water temperature
regulators. Test the antifreeze periodically for the concentration
of SCA. For the interval, refer to the Operation and
Check the glycol concentration to ensure adequate Maintenance Manual, “Maintenance Interval
protection against boiling or freezing. Perkins Schedule” (Maintenance Section). Cooling System
recommends the use of a refractometer for checking Supplemental Coolant Additive (SCA) Test/Add.
the glycol concentration. A hydrometer should not be
used. Additions of SCA are based on the results of the test.
The size of the cooling system determines the
Perkins engine cooling systems should be tested at amount of SCA that is needed.
500-hour intervals for the concentration of SCA.
Use the equation that is in Table 13 to determine the
Additions of SCA are based on the results of the test. amount of SCA that is required, if necessary:
An SCA that is liquid may be needed at 500-hour Table 13
intervals.
Equation For Adding The SCA To The Heavy-Duty Coolant
For Maintenance
NOTICE
Do not mix types and brands of coolant. V × 0.023 = X

Do not mix brands and types of SCAs. V is the total volume of the cooling system.

Do not mix SCAs and Extenders. X is the amount of SCA that is required.

Only use SCAs or Extender approved by coolant

Table 14 is an example for using the equation that is
manufacturer and compatible with coolant.
in Table 13 .
Table 14

Adding the SCA to Heavy-Duty Coolant Example Of The Equation For Adding The SCA To The Heavy-
Duty Coolant For Maintenance
at the Initial Fill
Total Volume of the Multiplication Amount of SCA
Coolants conforming to ASTM D4985 and not Cooling System (V) Factor that is Required
conforming D6210 require the addition of SCA at (X)
initial fill.
15 L (4 US gal) × 0.023 0.35 L (11.7 oz)
Use the equation that is in Table 11 to determine the
amount of SCA that is required when the cooling
system is initially filled.
M0068760-05 69
Maintenance Section
Fluid Recommendations

Cleaning the System of Heavy-Duty • CFR Co-ordinating Fuel Research

Antifreeze • ULSD Ultra Low Sulfur Diesel
Note: Before corrosion inhibitors can be effective the • RME Rape Methyl Ester
cooling system must be free from rust, scale and
deposits. • SME Soy Methyl Ester
• Drain the cooling system. • EPA Environmental Protection Agency of
the United States
• Before filling the cooling system with acceptable
quality water, pre-dissolve the cleaning agent in • PPM Parts Per Million
the water. Use a non-foaming detergent to clean
oil contamination, consult your Perkins dealer for • DPF Diesel Particulate Filter
suitable product.
• v/v (volume of solute)/(volume of solution)
NOTICE • CFPP Cold Filter Plugging Point
Most commercial cooling system cleaning agents are
corrosive and their use is not recommended by • BTL Biomass to liquid
Perkins.
The cooling system must be thoroughly flushed with • GTL Gas to liquid
clean water after using cleaning agents.
• CTL Coal to liquid
Cleaning agents for marine or industrial cooling sys-
tem must not be used. These cleaning agents are • HVO Hydrotreated Vegetable Oil
veryaggressiveand can cause damage to cooling
system components. General Information

• Run the engine for approximately 30 minutes and NOTICE

then leave the engine to cool down. Every attempt is made to provide accurate, up-to-
date information. By use of this document you agree
• Take a sample of the solution from the cooling that Perkins Engines Company Limited is not respon-
system, drain the system. sible for errors or omissions.

• Allow the sample to sit for at least 30 minutes and

check for signs of oil and deposits. If oil and NOTICE
deposits are still present, repeat the procedure. These recommendations are subject to change with-
out notice. Contact your local Perkins distributor for
• Flush the system with clean water. the most up-to-date recommendations.

• Fill the system with new coolant.

Diesel Fuel Requirements
i07835649
Perkins is not in a position to continuously evaluate
Fluid Recommendations and monitor all worldwide distillate diesel fuel
specifications that are published by governments and
(General Fuel Information) technological societies.
The “Perkins Specification for Distillate Diesel Fuel”
provides a known reliable baseline to judge the
expected performance of distillate diesel fuels that
are derived from conventional sources.
• Glossary
Satisfactory engine performance depends on the use
• ISO International Standards Organization of a good quality fuel. The use of a good quality fuel
will give the following results: long engine life and
• ASTM American Society for Testing and acceptable exhaust emissions levels. The fuel must
Materials meet the minimum requirements that are stated in
the table 15 .
• HFRR High Frequency Reciprocating Rig
for Lubricity testing of diesel fuels

• FAME Fatty Acid Methyl Esters

70 M0068760-05
Maintenance Section
General Fuel Information

NOTICE
The footnotes are key part of the Perkins "Specifica-
tion for Distillate Diesel Fuel" Table. Read ALL of the
footnotes.

Table 15
"Perkins Specification for Distillate Diesel Fuel"

Property UNITS Requirements “ASTM”Test “ISO/Other”Test

Aromatics %Volume 35% maximum “D1319” “ISO 3837”

Ash %Weight 0.01% maximum “D482” “ISO 6245”

Carbon Residue on 10% %Weight 0.20% maximum “D524” “ISO 4262”

Bottoms
Cetane Number(1) - 40 minimum in North “D613 or D6890” “ISO 5165”
America
45 minimum in European
Union
Cloud Point °C The cloud point must not “D2500” “ISO 3015”
exceed the lowest expected
ambient temperature.

Copper Strip Corrosion - No. 3 maximum “D130” “ISO 2160”

Distillation °C 50% at 250° C (482° F) “D86” “ISO 3405”

minimum
90% at 350° C (662° F)
maximum
Density at 15 °C (59 °F) (2) kg/M3 800 minimum and 860 No equivalent test “ISO 3675”“ISO 12185”
maximum
Flash Point °C legal limit “D93” “ISO 2719”

Thermal Stability - Minimum of 80% reflec- “D6468” No equivalent test

tance after aging for 180 mi-
nutes at 150 °C (302 °F)

Pour Point °C 6 °C (42.8 °F) minimum be- “D97” “ISO 3016”

low ambient temperature

Sulfur(3) %mass 0.0010 % Stage V Europe “D5453” “ISO 20846”

and 0.0015 % Tier 4 Final
North America
Kinematic Viscosity (4) MM2/S (cSt) The viscosity of the fuel that “D445” “ISO 3405”
is delivered to the fuel injec-
tion pump. 1.4 minimum
and 4.5 maximum
Water and sediment % weight 0.05% maximum “D1796” “ISO 3734”

Water % weight 0.02% maximum “D1744” No equivalent test

Sediment % weight 0.05% maximum “D473” “ISO 3735”

Gums and Resins (5) mg/100mL 10 mg per 100 mL “D381” “ISO 6246”
maximum
Lubricity correctedwear mm 0.52 maximum “D6079” “ISO 12156-1”
scar diameter at 60 °C
(140 °F). (6)

(continued)
M0068760-05 71
Maintenance Section
General Fuel Information

(Table 15, contd)

Fuel Cleanliness (7) - “ISO 18/16/13” “D7619” “ISO 4406”

Trace Metals (8) mg/mg Max 1 or non-detectable “D7111”

Oxidation Stability g/m^3 Max 25 “D2274” “ISO 12205”

Hours(9) Min 20 “EN 15751”

(1) To insure minimum cetane number of 40 a distillate diesel fuel should have minimum cetane index of 44 when“ASTM D4737” test method is
used. A fuel with a higher cetane number is recommended to operate at a higher altitude or in cold weather
(2) Density range allowed includes summer and winter diesel fuel grades.
(3) Follow the national, state, local, and other governing authorities for guidance concerning the fuel requirements in your area. In Europe for
non-road Stage V emissions regulations require sulfur free diesel fuels with sulphur content less than 0.0010 percent (10 PPM) (mg/kg)). In
the USA, EPA regulations require use of ULSD fuel with less than 0.0015 percent (15 PPM) (mg/kg)) sulfur content. Use of diesel fuel with
higher than 15 PPM sulphur limit in these engines will harm or permanently damage emissions control systems and/or shorten their service
interval.
(4) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscos-
ity requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the “ASTM D445” test method or
the “ISO 3104” test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain “1.4 cSt”or greater viscosity
at the fuel injection pump. Fuels with a high viscosity might require fuel heaters to lower the viscosity to “1.4 cSt” at the fuel injection pump.
(5) Follow the test conditions and procedures for gasoline (motor).
(6) The lubricity of a fuel is a concern with low sulfer and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or ASTM
D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel
supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in
the fuel system.
(7) Recommended cleanliness level for fuel as dispensed into machine or engine fuel tank is“ISO 18/16/13”or cleaner as per “ISO 4406”. Refer
to the “Contamination Control Recommendations for Fuels.
(8) Examples of trace metals include but not limited to Cu, Fe, Mn, Na, P, Pb, Si, and Zn. Use of metal-based additives is not allowed.
(9) Additional limit for fuel containing FAME. Fuel containing more than 2% v/v FAME must meet both tests.

Note: The owner and the operator of the engine has

the responsibility of using the fuel that is prescribed
by the EPA and other appropriate regulatory
agencies.

NOTICE
Operating with fuels that do not meet the Perkins rec-
ommendations can cause the following effects: Start-
ing difficulty, reduced fuel filter service life, poor
combustion, deposits in the fuel injectors, signifi-
cantly reduce service life of the fuel system. Also, the
creation of deposits in the combustion chamber and
reduced service life of the engine.

Engines that are manufactured by Perkins are Illustration 57 g02157153

certified with the fuel that is prescribed by the United
States Environmental Protection Agency. Engines Illustration 57 is a representation of the label that will
that are manufactured by Perkins are certified with be installed next to the fuel filler cap on the fuel tank
the fuel that is prescribed by the European of the application.
Certification. Perkins does not certify diesel engines
on any other fuel. The fuel specifications that are listed in the table 16
are released as acceptable to use on all 2806J series
NOTICE of engine.
The Perkins 2806J series of diesel engine must be
operated using Ultra Low Sulfur Diesel. The sulphur
content of this fuel must be lower than 15 PPM. This
fuel complies with the emissions regulations that are
prescribed by the Environmental Protection Agency
of the United States. In Europe, sulfur free diesel
fuels with sulphur content less than 0.0010 percent
(10 PPM) (mg/kg)) is required by regulation for use in
engines certified to EU nonroad Stage V emissions.
72 M0068760-05
Maintenance Section
General Fuel Information

Table 16
Acceptable Fuel Specification for the 2806J Engines(1)

Fuel Specification Comments

EN590 European Automotive Diesel Fuel (DERV)

“ASTM D975 GRADE 1D S15” “North American Light Distillate Diesel fuel with less than 15 PPM sul-
fur level”
“ASTM D975 GRADE 2D S15” “North American Middle Distillate general-purpose Diesel fuel with less
than 15 PPM sulfur level”
“JIS K2204” “Japanese Diesel Fuel” Must meet the requirements that are stated in
the section “Lubricity”.

“BS 2869: 2010 CLASS A2 or EU equivalent” “EU Off-Road Diesel fuel. Acceptable from 2011 MUST have less than
10 PPM sulfur level”
(1) All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel.

Diesel Fuel Characteristics The viscosity of the fuel is significant because fuel
serves as a lubricant for the fuel system components.
Cetane Number Fuel must have sufficient viscosity to lubricate the
fuel system in both extremely cold temperatures and
Fuel that has a high cetane number will give a shorter extremely hot temperatures. If the kinematic viscosity
ignition delay. A high cetane number will produce a of the fuel is lower than “1.4 cSt” at the fuel injection
better ignition quality. Cetane numbers are derived pump, damage to the fuel injection pump can occur.
for fuels against proportions of cetane and This damage can be excessive scuffing and seizure.
heptamethylnonane in the standard CFR engine. Low viscosity may lead to difficult hot restarting,
Refer to “ISO 5165” for the test method. stalling, and loss of performance. High viscosity may
In Europe for non-road Stage V emissions result in seizure of the pump.
regulations require minimum cetane number of 45. In Perkins recommends kinematic viscosities of 1.4 and
the North America, minimum cetane number 4.5 mm2/sec that is delivered to the fuel injection
requirement is 40. pump. If a fuel with a low viscosity is used, cooling of
Cetane number affect engine cold start ability, the fuel may be required to maintain 1.4 cSt or
exhaust emissions, combustion noise, and altitude greater viscosity at the fuel injection pump. Fuels with
performance. Fuel with a higher cetane number is a high viscosity might require fuel heaters to lower
desirable and recommended. This is particularly the viscosity to 4.5 cSt at the fuel injection pump.
important for operations in cold weather and at high
altitude. Density
Viscosity Density is the mass of the fuel per unit volume at a
specific temperature. This parameter has a direct
Viscosity is the property of a liquid of offering influence on engine performance and a direct
resistance to shear or flow. Viscosity decreases with influence on emissions. This influence determines
increasing temperature. This decrease in viscosity from a heat output given injected volume of fuel. This
follows a logarithmic relationship for normal fossil parameter is quoted in the following kg/m3 at 15 °C
fuel. The common reference is to kinematic viscosity. (59 °F).
Kinematic viscosity is the quotient of the dynamic
viscosity that is divided by the density. The Perkins recommends a density of 841 kg/m 3 to
determination of kinematic viscosity is normally by obtain the correct power output. Lighter fuels are
readings from gravity flow viscometers at standard acceptable but these fuels will not produce the rated
power.
temperatures. Refer to “ISO 3104” for the test
method.
Sulfur
The level of sulfur is governed by emissions
legislations. Regional regulation, national
regulations, or international regulations can require a
fuel with a specific sulfur limit. The sulfur content of
the fuel and the fuel quality must comply with all
existing local regulations for emissions.
M0068760-05 73
Maintenance Section
General Fuel Information

Perkins 2806J Series diesel engines have been Recommendation for Biodiesel and
designed to operate only with ULSD. By using the Using B20
test methods “ASTM D5453, or ISO 20846”, the
content of sulfur in ULSD fuel must be below 15 PPM
(mg/kg) or 0.0015% mass. Biodiesel is a fuel that can be defined as mono-alkyl
esters of fatty acids. Biodiesel is a fuel that can be
In the USA, EPA regulations require the use of ULSD made from various feedstocks. The most commonly
fuel with less than 0.0015 percent (15 PPM) (mg/kg)) available biodiesel in Europe is Rape Methyl Ester
sulfur content. (RME). This biodiesel is derived from rapeseed oil.
Soy Methyl Ester (SME) is the most common
In Europe, sulfur free diesel fuels with sulphur biodiesel in the United States. This biodiesel is
content less than 0.0010 percent (10 PPM) (mg/kg)) derived from soybean oil. Soybean oil or rapeseed oil
is required by regulation for use in engines certified to are the primary feedstocks. These fuels are together
EU nonroad Stage V emissions. known as Fatty Acid Methyl Esters (FAME).

NOTICE Raw pressed vegetable oils are NOT acceptable for

Use of diesel fuel with higher than 15 PPM sulphur use as a fuel in any concentration in compression
limit in these engines will harm or permanently dam- engines. Without esterification, these oils solidify in
age emissions control systems and/or shorten serv- the crankcase and the fuel tank. These fuels may not
ice interval. be compatible with many of the elastomers that are
used in engines that are manufactured today. In
original forms, these oils are not suitable for use as a
fuel in compression engines. Alternate base stocks
Lubricity for biodiesel may include animal tallow, waste
cooking oils, or various other feedstocks. To use any
Lubricity is the capability of the fuel to prevent pump of the products that are listed as fuel, the oil must be
wear. The fluids lubricity describes the ability of the esterified.
fluid to reduce the friction between surfaces that are
under load. This ability reduces the damage that is Fuel made of 100 percent FAME is generally referred
caused by friction. Fuel injection systems rely on the to as B100 biodiesel or neat biodiesel.
lubricating properties of the fuel. Until fuel sulfur limits
were mandated, the fuels lubricity was generally Biodiesel can be blended with distillate diesel fuel.
believed to be a function of fuel viscosity. The blends can be used as fuel. The most commonly
available biodiesel blends are B5, which is 5 percent
The lubricity has particular significance to the current biodiesel and 95 percent distillate diesel fuel. B20,
ultra low sulfur fuel, and low aromatic fossil fuels. which is 20 percent biodiesel and 80 percent distillate
These fuels are made to meet stringent exhaust diesel fuel.
emissions.
Note: The percentages given are volume-based.
The lubricity of these fuels must not exceed wear
scar diameter of 0.52 mm (0.0205 inch). The fuel The U.S. distillate diesel fuel specification “ASTM
lubricity test must be performed on an HFRR, D975-09a” includes up to B5 (5 percent) biodiesel.
operated at 60 °C (140 °F). Refer to “ISO 12156-1”.
European distillate diesel fuel specification EN590:
NOTICE 2010 includes up B7 (7 percent) biodiesel.
The fuels system has been qualified with fuel having
lubricity up to 0.52 mm (0.0205 inch) wear scar diam- Note: Engines that are manufactured by Perkins are
eter as tested by “ISO 12156-1”. Fuel with higher certified by use of the prescribed Environmental
wear scar diameter than 0.52 mm (0.0205 inch) will Protection Agency (EPA) and European Certification
lead to reduced service life and premature failure of fuels. Perkins does not certify engines on any other
the fuel system. fuel. The user of the engine has the responsibility of
using the correct fuel that is recommended by the
manufacturer and allowed by the EPA and other
Fuel additives can enhance the lubricity of a fuel. appropriate regulatory agencies.
Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier Specification Requirements
can make recommendations for additives to use, and
for the proper level of treatment.
The neat biodiesel must conform to the latest
“EN14214 or ASTM D6751” (in the USA). The
Distillation biodiesel can only be blended in mixture of up to 20%
by volume in acceptable mineral diesel fuel meeting
Distillation is an indication of the mixture of different latest edition of “EN590 or ASTM D975 S15”
hydrocarbons in the fuel. A high ratio of lightweight designation.
hydrocarbons can affect the characteristics of
combustion.
74 M0068760-05
Maintenance Section
General Fuel Information

In Europe diesel blends up to B20 must meet the Performance Related Issues
requirements listed in the latest edition of “EN16709”
B20 specification. Due to the lower energy content than the standard
distillate fuel B20 will cause a power loss in order of 2
In United States Biodiesel blends of B6 to B20 must to 4 percent. In addition, over time the power may
meet the requirements listed in the latest edition of deteriorate further due to deposits in the fuel
“ASTM D7467” (B6 to B20) and must be of an API injectors.
gravity of 30-45.
Biodiesel and biodiesel blends are known to cause
In North America biodiesel and biodiesel blends must an increase in fuel system deposits, most significant
be purchased from the BQ-9000 accredited of which are deposits within the fuel injector. These
producers and BQ-9000 certified distributors. deposits can cause a loss in power due to restricted
or modified fuel injection or cause other functional
In other areas of the world, the use of biodiesel that is issues associated with these deposits.
BQ-9000 accredited and certified, or that is
accredited and certified by a comparable biodiesel
Note: Perkins Fuel Cleaner (part number T400012)
quality body to meet similar biodiesel quality
standards is required. is most effective in cleaning and preventing the
formation of deposits. Perkins Diesel Fuel
Engine Service Requirements Conditioner helps to limit deposit issues by improving
the stability of biodiesel and biodiesel blends. For
Aggressive properties of biodiesel fuel may cause more information refer to “Perkins Diesel Fuel
debris in the fuel tank and fuel lines. The aggressive System Cleaner, and Perkins”.
properties of biodiesel will clean the fuel tank and fuel
lines. This cleaning of the fuel system can Biodiesel fuel contains metal contaminants (sodium,
prematurely block of the fuel filters. Perkins potassium, calcium, and/or magnesium) that form
recommend that after the initial usage of B20 ash products upon combustion in the diesel engine.
biodiesel blended fuel the fuel filters must be The ash can have an impact on the life and
replaced at 50 hours. performance of aftertreatment emissions control
devices and can accumulate in DPF. The ash
Glycerides present in biodiesel fuel will also cause accumulation may cause the need for more frequent
fuel filters to become blocked more quickly. Therefore ash service intervals and cause loss of performance
the regular service interval should be reduced to 250
hours. General Requirements
When biodiesel fuel is used, crank case oil and Biodiesel has poor oxidation stability, which can
aftertreatment systems may be influenced. This result in long-term problems in the storage of
influence is due to the chemical composition and biodiesel. Biodiesel fuel should be used within 6
characteristics of biodiesel fuel, such as density and months of manufacture. Equipment should not be
volatility, and to chemical contaminants that can be stored with the B20 biodiesel blends in the fuel
present in this fuel, such as alkali and alkaline metals system for longer than 3 months.
(sodium, potassium, calcium, and magnesium).
Due to poor oxidation stability and other potential
• Crankcase oil fuel dilution can be higher when issues, it is strongly recommended that engines with
biodiesel or biodiesel blends are used. This limited operational time either not use B20 biodiesel
increased level of fuel dilution when using blends or, whilst accepting some risk, limit biodiesel
biodiesel or biodiesel blends is related to the blend to a maximum of B5. Examples of applications
typically lower volatility of biodiesel. In-cylinder that should limit the use of biodiesel are the following:
emissions control strategies utilized in many of the Standby Generator sets and certain emergency
industrial latest engine designs may lead to a vehicles.
higher level of biodiesel concentration in the For standby generator sets and emergency vehicles
sump. The long-term effect of biodiesel that cannot avoid use of biodiesel blends fuel quality
concentration in crankcase oil is unknown in the engine fuel tank must be sampled and checked
currently. monthly. Test should include acid number
(EN14104), oxidation stability (EN 15751 commonly
• Perkins recommend the use of oil analysis to know as the Rancimant test), and sediment
check the quality of the engine oil if biodiesel fuel (ISO12937). For standby generator sets oxidation
is used. Ensure that the level of biodiesel in the stability of biodiesel blend must be 20 hours or more
fuel is noted when the oil sample is taken. as per EN 15751. If the test shows that the fuel has
degraded, fuel tank must be drained and engine
flashed by running with the fresh high-quality diesel
fuel.
M0068760-05 75
Maintenance Section
General Fuel Information

Perkins strongly recommends that seasonally Ensure that the fuel has got appropriate cold flow
operated engines have the fuel systems, including properties (cloud point and CFPP) for the minimum
fuel tanks, flashed with conventional diesel fuel statistical ambient temperature the engine is
before prolonged shutdown periods. An example of expected to see in the operation. The Fuel must also
an application that should seasonally flush the fuel meet lubricity requirements as specified in the
system is a combine harvester. lubricity section of this “Operation and Maintenance
Manual” Fluid Recommendations
Microbial contamination and growth can cause
corrosion in the fuel system and premature plugging Fuel for Cold-Weather Operation
of the fuel filter. Consult your supplier of fuel for
assistance in selecting appropriate anti-microbial
additive. The European standard “EN590” contains climate
dependant requirements and a range of options. The
Water accelerates microbial contamination and options can be applied differently in each country.
growth. When biodiesel is compared to distillate There are five classes that are given to arctic
fuels, water is naturally more likely to exist in the climates and severe winter climates. 0, 1, 2, 3 and 4.
biodiesel. Therefore check frequently and if
necessary, drain the water separator. Fuel that complies with “EN590” CLASS 4 can be
used at temperatures as low as −44 °C (−47.2 °F).
Materials such as brass, bronze, copper, lead, tin, Refer to “EN590” fora detailed discretion of the
and zinc accelerate the oxidation process of the physical properties of the fuel.
biodiesel fuel. The oxidation process can cause
deposits formation therefore these materials must not The diesel fuel “ASTM D975 1-D” used in the United
States of America may be used in very cold
be used for fuel tanks and fuel lines. temperatures that are below −18 °C (−0.4 °F).
Renewable and Alternative Fuels Aftermarket Fuel Additives
Perkins supports development and use of renewable
fuels through sustainability initiatives. In recent years NOTICE
various forms of renewable and alternative Perkins does not warrant the quality or performance
(synthetic) diesel fuels have started to emerge. of non-Perkins fluids and filters.
Synthetic diesel fuels are produced by gasification of When auxiliary devices, accessories, or consum-
various feedstock and then synthesis to liquid to ables (filters, additives) which are made by other
obtain paraffinic diesel fuel. Based on the feedstock manufacturers are used on Perkins products, the
used these fuels are commonly referred to as Perkins warranty is not affected simply because of
Biomass to liquid (BTL), Gas to liquid (GTL) and Coal such use.
to liquid (CTL). Hydrotreating of vegetable oils and
animal fats is another emerging process for However, failures that result from the installation
production of bio based diesel fuel called or use of other manufacturers devices, accesso-
Hydrotreated Vegetable Oil (HVO). ries, or consumables are NOT Perkins defects.
Therefore, the defects are NOT covered under the
Perkins warranty.
BTL and HVO fuels are considered to be low carbon
fuels as they reduce carbon foot print compared to
Supplemental diesel fuel additives are not generally
fossil fuels and are commonly referred to as
recommended. This recommendation is due to
renewable fuels. These fuels must not be confused potential damage to the fuel system or the engine.
with biodiesel FAME which is fundamentally different
Your fuel supplier or the fuel manufacturer will add
fuel and is discussed in a separate section in this
the appropriate supplemental diesel fuel additives.
manual.
These paraffinic fuels have virtually no sulphur or Perkins recognizes the fact that additives may be
aromatics and have very high cetane numbers which required in some special circumstances.
enable very clean burning and efficient engine
operation. Chemically these fuels are similar to diesel Note: Some anti-corrosion additives can lead to
fuel derived form petroleum and are therefore injector fouling, this fouling can cause the injector to
suitable to use in diesel engines as a replacement or operate incorrectly.
blend stock with conventional diesel fuel. To be
acceptable renewable and alternative fuels must Contact your fuel supplier for those circumstances
meet latest edition of the paraffinic diesel fuel when fuel additives are required. Your fuel supplier
specification “CENTS 15940”. The fuel should also can recommend the appropriate fuel additive and the
meet requirements described in table 15 , Perkins correct level of treatment.
Specification for Distillate Diesel Fuel, EN590, or
latest ASTM D975 specification. Note: For the best results, your fuel supplier should
treat the fuel when additives are required. The
treated fuel must meet the requirements that are
stated in table 15 .
76 M0068760-05
Maintenance Section
General Fuel Information

Perkins Diesel Fuel System Cleaner Water in the fuel causes cavitation, corrosion of fuel
system parts, and provides an environment where
Perkins Fuel Cleaner (part number T400012) is the microbial growth in the fuel can flourish. Other
only fuel cleaner that is recommended by Perkins. sources of fuel contamination are soaps, gels, or
other compounds that may result from undesirable
If biodiesel or biodiesel blends of fuel are to be used, chemical interactions in the fuels, particularly in
Perkins require the use of Perkins fuel cleaner. The ULSD. Gels and other compounds can also form in
use of the fuel is to remove deposits within the fuel biodiesel fuel at low temperatures or if biodiesel is
system that is created with the use of biodiesel. For stored for extended periods. The best indication of
more information on the use of biodiesel and microbial contamination, fuel additives, or cold
biodiesel blends refer to “Recommendation for temperature gel is rapid filter plugging of bulk fuel
Biodiesel and Using B20”. filters or application fuel filters.
Perkins fuel cleaner will remove deposits that can To reduce downtime due to contamination, follow
form in the fuel system with the use of biodiesel and these fuel maintenance guidelines.
biodiesel blends. These deposits can create a loss of
power and engine performance. • Use high-quality fuels per recommended and
required specifications
Once the fuel cleaner has been added to the fuel, the
deposits within the fuel system are removed after 30 • Fill fuel tanks with fuels of “ISO 18/16/13”
hours of engine operation. For maximum results, cleanliness level or cleaner, in particular for
continue to use the fuel cleaner for up to 80 hours. engines with common rail and unit injection
Perkins fuel cleaner can be used on an on-going systems. When you refuel the tank, filter the fuel
basis with no adverse impact on engine or fuel
through a 4 µm absolute filter (Beta 4 = 75 up to
system durability.
200) to reach the recommended cleanliness level.
Detailed instructions on the rate of which the fuel This filtration should be installed at the device that
cleaner must be used are on the container. dispenses the fuel to the fuel tank. In addition,
filtration at the dispensing point should remove
Note: Perkins fuel cleaner is compatible with existing water to ensure that fuel is dispensed at 500 ppm
and U.S. EPA Tier 4 nonroad certified diesel engine water or less.
emission control catalysts and particulate filters.
Perkins fuel system cleaner contains less than 15 • Perkins recommends the use of bulk fuel filter /
ppm of sulfur and is acceptable for use with ULSD coalescer units which clean the fuel of both
fuel. particulate contamination and water in a single
pass.
Contamination Control • Ensure that you use Perkins Advanced Efficiency
Recommendations for Fuels Fuel Filters. Change your fuel filters per
recommended service requirements or as needed.
Fuels of “ISO 18/16/13” cleanliness level or cleaner
as dispensed into the engine or application fuel tank • Drain your water separators daily.
should be used. This will reduce risk of power loss,
fuel system failures, and related down time of • Drain your fuel tanks of sediment and water per
engines. This cleanliness level is important for new the Operation and Maintenance Manual
fuel system designs such as common rail injection instructions.
systems and unit injectors. These fuels systems
utilize higher fuel injection pressures and have tight • Install and maintain a properly designed bulk filter
clearances between moving parts to meet required / coalescer filtration system. Continuous bulk
stringent emissions regulations. Peak injection filtration systems may be required to ensure that
pressures in current fuel injection systems may dispensed fuel meets the cleanliness target.
exceed 2000 bar (29000 psi). Clearances in these
Consult your Perkins distributor for availability of
systems are less than 5 µm. As a result, particle
contaminants as small as 4 µm can cause scoring bulk filtration products.
and scratching of internal pump and injector surfaces
• Centrifugal filters may need to be used as a pre-
and of injector nozzles.
filter with fuel that is severely contaminated with
gross amounts of water and/or large particulate
contaminants. Centrifugal filters can effectively
remove large contaminants. Centrifugal filters may
not be able to remove the small abrasive particles
required to achieve the recommended “ISO”
cleanliness level. Bulk filter / coalescers are
necessary as a final filter to achieve the
recommended cleanliness level.
M0068760-05 77
Maintenance Section
Refill Capacities and Recommendations

• Install desiccant type breathers of 4 µm or less

absolute efficiency with the ability to remove water
on bulk storage tanks.

• Follow proper practices of fuel transportation.

Filtration from the storage tank to the application
promotes the delivery of clean fuel. Fuel filtration
can be installed at each transport stage to keep
the fuel clean.
Illustration 60 g02300474

• Cover, protect, and ensure cleanliness of all Deep pan

connection hoses, fittings, and dispensing
nozzles. The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
Consult your local Perkins distributor for additional plus standard oil filters. Auxiliary oil filter systems will
information on Perkins designed and produced require extra oil. Refer to the OEM specifications for
filtration products. the capacity of the auxiliary oil filter.
Table 17
i06937316
2000 Series Industrial Engines
Approximate Refill Capacities
Refill Capacities and
Engine with 1 Engine with 2
Recommendations Oil Sump(1)
Filter Filters
Standard pan 34 L (36 qt) 43 L (45 qt)

Center pan 60 L (63 qt) 62 L (66 qt)

Refill Capacities
Deep pan 68 L (72 qt) 70 L (74 qt)
Lubricant Refill Capacity (1) These values are approximate capacities for the crankcase oil
sump which include the standard oil filters that are installed at
the factory. Engines with auxiliary oil filters will require extra oil.
Refer to the OEM specifications for the capacity of the auxiliary
oil filter.

Coolant Refill Capacity

To maintain the cooling system, the total cooling
system capacity must be known. The capacity of the
total cooling system will vary. The capacity will
depend on the size of the radiator (capacity). Table
18 should be completed by the customer for the
maintenance of the cooling system.
Table 18
Approximate Capacity of the Cooling System

Compartment or
Illustration 58 g02300456 Liters Quarts
System
Standard pan
Total Cooling System
(1)

(1) The total cooling system capacity includes the following compo-
nents: The engine block, the radiator, and all coolant hoses and
lines.

Recommendation
Refer to this Operation and Maintenance Manual,
Illustration 59 g02300473
“Fluid Recommendations” for information about the
fluids which are acceptable for this engine.
Center pan
78 M0068760-05
Maintenance Section
Maintenance Recommendations

Maintenance Do not loosen the high pressure fuel lines in order to

remove air pressure from the fuel system.
Recommendations
Engine Oil
i02909163
To relieve pressure from the lubricating system, turn
System Pressure Release off the engine.

i07677878

Coolant System Welding on Engines with

Electronic Controls
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- NOTICE
diator is cool. Then loosen cap slowly to relieve Because the strength of the frame may decrease,
the pressure. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Perkins dealer regarding welding on a
off the engine. Allow the cooling system pressure cap chassis frame or rail.
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure. Correct welding procedures are necessary to avoid
damage to the engines ECM, sensors, and
Fuel System associated components. When possible, remove the
component from the unit and then weld the
component. If removal of the component is not
To relieve the pressure from the fuel system, turn off possible, the following procedure must be followed
the engine. when you weld on a unit equipped with an Electronic
Engine. The following procedure is considered to be
High Pressure Fuel Lines (If Equipped) the safest procedure to weld on a component. This
procedure should provide a minimum risk of damage
to electronic components.

Contact with high pressure fuel may cause fluid NOTICE

Do not ground the welder to electrical components
penetration and burn hazards. High pressure fuel
such as the ECM or sensors. Improper grounding
spray may cause a fire hazard. Failure to follow
can cause damage to the drive train bearings, hy-
these inspection, maintenance and service in-
draulic components, electrical components, and oth-
structions may cause personal injury or death. er components.
The high pressure fuel lines are the fuel lines that are Clamp the ground cable from the welder to the com-
between the high pressure fuel pump and the high ponent that will be welded. Place the clamp as close
pressure fuel manifold and the fuel lines that are as possible to the weld. This will help reduce the pos-
between the fuel manifold and cylinder head. These sibility of damage.
fuel lines are different from fuel lines on other fuel
systems.
This is because of the following differences: Note: Perform the welding in areas that are free from
explosive hazards.
• The high pressure fuel lines are constantly
charged with high pressure. 1. Stop the engine. Turn the switched power to the
OFF position.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system. 2. Ensure that the fuel supply to the engine is turned
off.
Before any service or repair is performed on the
engine fuel lines, perform the following tasks: 3. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
1. Stop the engine. open the switch.
2. Wait for ten minutes. 4. Disconnect all electronic components from the
wiring harnesses. Include the following
components:
M0068760-05 79
Maintenance Section
Severe Service Application

• Electronic components for the driven 5. Connect the welding ground cable directly to the
equipment part that will be welded. Place the ground cable as
close as possible to the weld to reduce the
• ECM possibility of welding current damage to the
following components. Bearings, hydraulic
• Sensors
components, electrical components, and ground
• Electric operated fuel pump straps.

• Electronically controlled valves Note: If electrical/electronic components are used as

a ground for the welder, or electrical/electronic
• Relays components are located between the welder ground
and the weld, current flow from the welder could
• Aftertreatment ID module severely damage the component.

6. Protect the wiring harness from welding debris and

NOTICE
Do not use electrical components (ECM or ECM sen- spatter.
sors) or electronic component grounding points for 7. Use standard welding practices to weld the
grounding the welder.
materials.

i07014325

Severe Service Application

Severe service is the application of an engine that

either exceeds the current published standards for
that engine range. Or results in the engine being
used at the extremes of certain operating conditions.

• Performance such as power range, speed range,

and fuel consumption

• Fuel quality
• Operational Altitude
• Maintenance intervals

• Oil selection and maintenance

• Coolant type and maintenance
Illustration 61 g06392357 • Environmental qualities
Use the example above. The current flow from the
welder to the ground clamp of the welder will not • Installation
damage any associated components.
(1) Engine
• The temperature of the fluid in the engine
(2) Welding electrode
(3) Keyswitch in the OFF position Refer to the standards for the engine or consult your
(4) Battery disconnect switch in the open position Perkins distributor to determine if the engine is
(5) Disconnected battery cables operating within the defined parameters.
(6) Battery
(7) Electrical/Electronic component Severe service operation can accelerate component
(8) The component that is being welded wear. Engines that operate under severe conditions
(9) Current path of the welder may need more frequent maintenance intervals to
(10) Ground clamp for the welder
ensure maximum reliability and retention of full
service life.
80 M0068760-05
Maintenance Section
Severe Service Application

Due to individual applications, identification is not

possible for all the factors which can contribute to
severe service operation. Consult your Perkins
distributor for the unique maintenance that is
necessary for the engine.
The operating environment, incorrect operating
procedures, and incorrect maintenance procedures
can be factors which contribute to a severe service
application.

Environmental Factors
Ambient temperatures – The engine may be
exposed to extended operation in extremely cold
environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
cold temperatures. Extremely hot intake air reduces
engine performance.
Quality of the air – The engine may be exposed to
extended operation in an environment that is dirty or
dusty, unless the equipment is cleaned regularly.
Mud, dirt, and dust can encase components.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals.
Buildup – Compounds, elements, corrosive
chemicals, and salt can damage some components.
Altitude – Problems can arise when the engine is
operated at altitudes that are higher than the
intended settings for that application. Necessary
adjustments should be made.

Incorrect Operating Procedures

• Extended operation at low idle

• Frequent hot shutdowns

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application

Incorrect Maintenance Procedures

• Extending the maintenance intervals
• Failure to use recommended fuel, lubricants, and
coolant/antifreeze
M0068760-05 81
Maintenance Section
Maintenance Interval Schedule

i07508723 “ Hoses and Clamps - Inspect/Replace”. . . . . . . . 108

Maintenance Interval Schedule Every 500 Service Hours or 3

Months
“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 87
When Required
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . . 85 Every 500 Service Hours or 1 Year
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 85 “ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 104
“ Battery or Battery Cable - Disconnect” . . . . . . . . . 86
“ Fuel System Secondary Filter - Replace”. . . . . . 106
“DEF Filler Screen (Emission Related Component) -
Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Every 2000 Service Hours
“Diesel Exhaust Fluid (Emission Related Component)
- Fill” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 “ Air Shutoff - Test” . . . . . . . . . . . . . . . . . . . . . . . . . . 84
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Every 2500 Service Hours
“ Engine Air Cleaner Element - Replace” . . . . . . . . 98
“ Electronic Unit Injector - Inspect/Adjust” . . . . . . . 97
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 104
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 103
“ Fuel Tank Water and Sediment - Drain” . . . . . . . 107
“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . 109 Every 3000 Service Hours or 3
Years
Daily
“ Cooling System Coolant (DEAC) - Change” . . . . 87
“ Air Tank Moisture and Sediment - Drain” . . . . . . . 85
“ Cooling System Coolant Level - Check”. . . . . . . . 90
Every 4000 Service Hours
“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . . 97 “ Air Compressor - Check”. . . . . . . . . . . . . . . . . . . . 84

“ Engine Air Cleaner Service Indicator - Inspect” . . 99 “ Engine Mounts - Ins pect” . . . . . . . . . . . . . . . . . . .100

“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 100 “ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . 109

“ Fuel System Primary Filter/Water Separator - Every 5000 Service Hours

Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . 109 “ARD Spark Plug (Emission Related Component) -
Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Every 250 Service Hours “Diesel Exhaust Fluid Filter (Emission Related
Component) - Replace” . . . . . . . . . . . . . . . . . . . . . . 95
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 101
“Diesel Particulate Filter (Emission Related
“Grounding Stud - Inspect/Clean/Tighten” . . . . . . 107 Component) - Clean” . . . . . . . . . . . . . . . . . . . . . . . . 97

Initial 500 Service Hours

“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 103

Every 500 Service Hours

“ Battery Electrolyte Level - Check” . . . . . . . . . . . . 86
“ Cooling System Supplemental Coolant Additive
(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 102
82 M0068760-05
Maintenance Section
Maintenance Interval Schedule

“Diesel Exhaust Fluid Injector (Emission Related

Component) - Replace” . . . . . . . . . . . . . . . . . . . . . . 97

Every 6000 Service Hours or 3

Years
“ Cooling System Coolant Extender (ELC) -
Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Every 10 000 Service Hours

“DEF Manifold Filters (Emission Related Component)
- Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Every 760 000 L (200 000 US gal) of

Fuel or 10 000 Service Hours
“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . 109

Every 12 000 Service Hours or 6

Years
“ Cooling System Coolant (ELC) - Change” . . . . . . 89
M0068760-05 83
Maintenance Section
ARD Spark Plug (Emission Related Component) - Clean

i07508570 2. Debris may have collected in the spark plug well.

Thoroughly remove any debris. Use compressed
ARD Spark Plug (Emission air. The maximum air pressure for cleaning
Related Component) - Clean purposes must be below 205 kPa (30 psi). Ensure
that the area around the spark plug is clean and
free of dirt and debris.
3. Use a 22 mm (0.86 inch)22mm spark plug socket
and a breaker bar to loosen the spark plug. After
Personal injury can result from air pressure. the spark plug has been loosened, use the spark
plug socket to remove the spark plug by hand to
Personal injury can result without following prop- detect problems with the threads. After the spark
er procedure. When using pressure air, wear a plug has been removed, inspect the used spark
protective face shield and protective clothing.
plug and the gasket.
The maximum air pressure for cleaning purposes
4. After removing the spark plug, clean the ground
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded. probe inside the ARD combustion head by running
a T400005 Plug Bore Brush through the hole in
the ARD combustion head. This tool scrapes
NOTICE debris from the seat and from the threads. Run the
If the engine is running or the key is in the ON posi- brush through the hole several times.
tion the Aftertreatment Regeneration Device (ARD)
plug will continue to fire. Turn the key to the OFF po- Note: The spark plug may be damaged if the spark
sition before servicing the ARD plug. plug is dropped. Do not install a spark plug that has
been dropped or a spark plug that is damaged.

Removing the Spark Plug 5. Carefully clean the spark plug using a nonmetallic
cleaning pad. If the probe appears to be bent,
replace the spark plug. Do not use a thread tap. A
thread tap will remove metal unnecessarily. The
threads could be stripped and the combustion
group could be damaged.

Installing the Spark Plug

Note: Do not use anti-seize compound on the spark
plug. Most of the heat is transferred through the
threads and the seat area of the spark plug. Contact
of the metal surfaces must be maintained to provide
the heat transfer that is required.

1. Ensure that the spark plug is clean and free of dirt

and oil.

NOTICE
Do not overtighten the spark plug. The shell can be
cracked and the gasket can be deformed. The metal
can deform and the gasket can be damaged. The
shell can be stretched. This will loosen the seal that
is between the shell and the insulator, allowing com-
Illustration 62 g06046854 bustion pressure to blow past the seal. Serious dam-
Typical example age to the engine can occur.
(1) Spark plug
(2) Wiring harness Use the proper torque.

1. Remove wire harness (2) from spark plug (1). 2. Install the spark plug (1) by hand until the spark
plug contacts the ARD. Tighten the spark plug to a
torque of 47 N·m (34 lb ft)
84 M0068760-05
Maintenance Section
Air Compressor - Check

3. Connect the wiring harness (2). The function of the pressure relief valve is to bypass
air when there is a malfunction in the system for the
i06111571 air compressor.
The pressure relief valve for the air compressor
Air Compressor - Check releases air at 1723 kPa (250 psi). If the pressure
(If Equipped) relief valve for the air compressor exhausts, all
personnel should be at a safe distance away from the
air compressor. All personnel should also stay clear
of the air compressor when the engine is operating
and the air compressor is exposed.
Consult your Perkins distributor for assistance.
Do not disconnect the air line from the air com-
pressor governor without purging the air brake
and the auxiliary air systems. Failure to purge the i07297207
air brake and the auxiliary air systems before re-
moving the air compressor and/or the air lines Air Shutoff - Test
could cause personal injury.

To ensure that the air shutoff valve always shuts

down when the engine ingests gaseous fumes,
perform the test below at each oil change. A test
failure can indicate wear in the block off plate to valve
body interface and/or the bearing system.
1. Place engine at low idle speed. Ensure all
accessories that are normally used for the
application are in use, like a fan, or power takeoffs.
2. Actuate the air shutoff manually. On electrical
operator air shutoffs, utilize an applicable power
supply or jumper cables from the battery to
energize the air shut-off solenoid. Ensure that the
solenoid receives only a momentary signal to
prevent overheating. On hydraulic operator air
shutoffs, found on some hazardous location units,
actuate by pulling the emergency stop handle.
3. Ensure that air shutoff was actuated and that the
engine comes to a complete stop.
Illustration 63 g03813903 Note: As every application has different parasitic
Typical example loads and inertia, the duration for the problem to
(1) Pressure relief valve occur cannot be specified. However, if the engine
stumbles or attempts to continue running, these
symptoms may be an indication that worn
components may need replacement.
If the air compressor pressure relief valve that is
mounted in the air compressor cylinder head is NOTICE
bypassing compressed air, there is a malfunction Actuating the air shutoff valve may result in oil leak-
in the air system, possibly ice blockage. Under age past the shaft seal in some cases. Repeated ac-
these conditions, your engine may have insuffi- tuation of the air shutoff valve during loaded
cient air for normal brake operation. operation of the engine can result in mechanical
damage to the turbocharger and reduce turbocharger
Do not operate the engine until the reason for the life.
air bypass is identified and corrected. Failure to
heed this warning could lead to property damage,
personal injury, or death to the operator or
bystanders.
M0068760-05 85
Maintenance Section
Air Tank Moisture and Sediment - Drain

i00847451 i01878164

Air Tank Moisture and Battery - Replace

Sediment - Drain
(If Equipped)
Batteries give off combustible gases which can
Moisture and sediment in the air starting system can explode. A spark can cause the combustible
cause the following conditions: gases to ignite. This can result in severe personal
injury or death.
• Freezing
Ensure proper ventilation for batteries that are in
• Corrosion of internal parts an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
• Malfunction of the air starting system near batteries. Do not smoke when batteries are
serviced.

When opening the drain valve, wear protective

gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could The battery cables or the batteries should not be
cause debris to be blown and result in personal removed with the battery cover in place. The bat-
injury. tery cover should be removed before any servic-
ing is attempted.
1. Open the drain valve that is on the bottom of the Removing the battery cables or the batteries with
air tank. Allow the moisture and sediment to drain. the cover in place may cause a battery explosion
resulting in personal injury.
2. Close the drain valve.
3. Check the air supply pressure. The air starting 1. Switch the engine to the OFF position. Remove all
motor requires a minimum of 620 kPa (90 psi) of electrical loads.
air pressure to operate properly. The maximum air
pressure must not exceed 1550 kPa (225 psi). 2. Turn off any battery chargers. Disconnect any
The normal air pressure will be 758 to 965 kPa battery chargers.
(110 to 140 psi). 3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the NEGATIVE “-” terminal
i02039199 on the starter motor. Disconnect the cable from the
NEGATIVE “-” battery terminal.
Battery - Recycle
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the POSITIVE “+” terminal
Always recycle a battery. Never discard a battery. on the starting motor. Disconnect the cable from
Return used batteries to one of the following the POSITIVE “+” battery terminal.
locations:
Note: Always recycle a battery. Never discard a
• A battery supplier battery. Return used batteries to an appropriate
recycling facility.
• An authorized battery collection facility
5. Remove the used battery.
• A recycling facility
6. Install the new battery.

Note: Before the cables are connected, ensure that

the engine start switch is OFF.

7. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.
86 M0068760-05
Maintenance Section
Battery Electrolyte Level - Check

8. Connect the cable from the NEGATIVE “-” terminal i05424317

on the starter motor to the NEGATIVE “-” battery
terminal. Battery or Battery Cable -
i02747977
Disconnect
Battery Electrolyte Level -
Check
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
When the engine is not run for long periods of time or tery cover should be removed before any servic-
when the engine is run for short periods, the batteries ing is attempted.
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries Removing the battery cables or the batteries with
are correctly charged, the ammeter reading should the cover in place may cause a battery explosion
be very near zero, when the engine is in operation. resulting in personal injury.

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

ignition switch (if equipped) to the OFF position
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a and remove the key and all electrical loads.
face shield and protective clothing when working
on or near batteries. Note: After the engine has stopped, allow 2 minutes
in order for the diesel exhaust fluid lines to be purged
before disconnecting the power.
1. Remove the filler caps. Maintain the electrolyte
level to the “FULL” mark on the battery. 2. Disconnect the negative battery terminal. Ensure
that the cable cannot contact the terminal. When
If the addition of water is necessary, use distilled four 12 V batteries are involved, 2 negative
water. If distilled water is not available use clean connections must be disconnected.
water that is low in minerals. Do not use artificially
softened water. 3. Remove the positive connection.

2. Check the condition of the electrolyte with a 4. Clean all disconnected connection and battery
suitable battery tester. terminals.

3. Install the caps. 5. Use a fine grade of sandpaper to clean the

terminals and the cable clamps. Clean the items
4. Keep the batteries clean. until the surfaces are bright or shiny. DO NOT
Clean the battery case with one of the following remove material excessively. Excessive removal
cleaning solutions: of material can cause the clamps to fit incorrectly.
Coat the clamps and the terminals with a suitable
• Use a solution of 0.1 kg (0.2 lb) baking soda silicone lubricant or petroleum jelly.
and 1 L (1 qt) of clean water.
6. Tape the cable connections in order to help
• Use a solution of ammonium hydroxide. prevent accidental starting.
7. Proceed with necessary system repairs.
Thoroughly rinse the battery case with clean
water. 8. In order to connect the battery, connect the
positive connection before the negative connector.
M0068760-05 87
Maintenance Section
Belts - Inspect/Adjust/Replace

i06934547 • More than one section of the belt is displaced in

one rib of a maximum length of 50.8 mm (2 inch)
Belts - Inspect/Adjust/Replace
Adjust
The engine is equipped with an automatic belt
tensioner (3). Manual adjustment of the belt is not
required.

Replace
The tensioner (3) has a square drive (2) that can be
used to remove the tension from the belt, allowing the
belt to be removed. For a full description on replacing
the belt refer to Disassembly and Assembly,
Alternator Belt - Remove and Install.

i06606846

Cooling System Coolant

(DEAC) - Change

Clean the cooling system and flush the cooling

system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.

• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
Illustration 64 g06046748
• The fuel has entered the cooling system and the
Typical example
coolant is contaminated.
(1) Belt
(2) Square drive Note: Inspect the water pump and the water
(3) Tensioner
temperature regulator after the cooling system has
been drained.
Inspect
To maximize the engine performance, inspect the
belt for wear and for cracking. Replace the belt if the
belt is worn or damaged.
• Inspect the belt for cracks, splits, glazing, grease,
displacement of the cord and evidence of fluid
contamination.
The belt must be replaced if the following conditions
are present.
• The belt has a crack in more than one rib.
88 M0068760-05
Maintenance Section
Cooling System Coolant (DEAC) - Change

NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

3. Fill the cooling system with clean water and

operate the engine, ensure that the thermostat
opens. Stop the engine and allow the engine to
cool.
4. Drain the cooling system.
5. Fill the cooling system with clean water and
operate the engine until the engine is warmed to
82 °C (180 °F).
6. Stop the engine and allow the engine to cool. Drain
the cooling system.

Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

1. Fill the cooling system with coolant/antifreeze.

Refer to this Operation and Maintenance Manual,
Illustration 65 g02351659 “Fluid Recommendations” topic for more
The cooling system drain valve is towards the bottom information on cooling system specifications. Do
of the radiator. not install the cooling system filler cap.
2. Start and run the engine at low idle. Increase the
Drain engine rpm to 1500 rpm. Run the engine at high
idle for 1 minute to purge the air from the cavities
of the engine block. Stop the engine.

Pressurized System: Hot coolant can cause seri- 3. Check the coolant level. Maintain the coolant level
ous burns. To open the cooling system filler cap, within 13 mm (0.5 inch) below the bottom of the
stop the engine and wait until the cooling system pipe for filling. Maintain the coolant level within
components are cool. Loosen the cooling system 13 mm (0.5 inch) to the proper level on the sight
pressure cap slowly in order to relieve the glass.
pressure.
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
1. Stop the engine and allow the engine to cool.
the gasket that is on the cooling system filler cap is
Loosen the cooling system filler cap slowly in
damaged, discard the old filler cap and install a
order to relieve any pressure. Remove the cooling
new filler cap. If the gasket that is on the cooling
system filler cap.
system filler cap is not damaged, perform a
2. Open the cooling system drain valve. pressure test. The correct pressure for the cooling
system filler cap is stamped on the face of the
Allow the coolant to drain.
cooling system filler cap. If the cooling system filler
cap does not retain the correct pressure, install a
Flush new cooling system filler cap.
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve.
M0068760-05 89
Maintenance Section
Cooling System Coolant (ELC) - Change

5. Start the engine and inspect the cooling system for

leaks and for proper operating temperature.

i06606848

Cooling System Coolant (ELC)

- Change

NOTICE
Perkins ELC must be using with an extender in order
to achieve 12000 hours operation. For more informa-
tion on a suitable extender contact your Perkins
distributor.

Clean the cooling system and flush the cooling

system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.

• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.

• The fuel has entered the cooling system and the

coolant is contaminated.
Illustration 66 g02351659

Note: When the cooling system is cleaned, only

clean water is needed when the ELC is drained and Drain
replaced.

Note: Inspect the water pump and the water

temperature regulator after the cooling system has
been drained. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.

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

Loosen the cooling system filler cap slowly to
relieve any pressure. Remove the cooling system
filler cap.
2. Open the cooling system drain valve.
Allow the coolant to drain.

Flush
1. Flush the cooling system with clean water to
remove any debris.
2. Close the drain valve.
90 M0068760-05
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

5. Start the engine and Inspect the cooling system for

NOTICE
Fill the cooling system no faster than 19 L (5 US gal) leaks and for proper operating temperature.
per minute to avoid air locks.
i06606850

3. Fill the cooling system with clean water. Install the Cooling System Coolant
cooling system filler cap.
Extender (ELC) - Add
4. Start and run the engine at low idle until the
temperature reaches 49 °C to 66 °C
(120 °F to 150 °F). For Perkins ELC to achieve 12000 hours an extender
must be added at 6000 hours. For a suitable
5. Stop the engine and allow the engine to cool. extender, contact your Perkins distributor.
Loosen the cooling system filler cap slowly to
relieve any pressure. Remove the cooling system i06606851
filler cap. Open the drain valve. Allow the water to
drain. Flush the cooling system with clean water. Cooling System Coolant Level
Close the drain valve.
- Check
Fill
Check the coolant level when the engine is stopped
NOTICE and cool.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

1. Fill the cooling system with Extended Life Coolant

(ELC). Refer to this Operation and Maintenance
Manual, “Fluid Recommendations” for more
information on cooling system specifications. Do
not install the cooling system filler cap.
2. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for 1 minute to purge the air from the cavities
of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the Illustration 67 g00285520

pipe for filling. Maintain the coolant level within Cooling system filler cap
13 mm (0.5 inch) to the proper level on the sight
glass.
4. Clean the cooling system filler cap. Inspect the
Pressurized System: Hot coolant can cause seri-
gasket that is on the cooling system filler cap. Only ous burns. To open the cooling system filler cap,
install the used filler cap if the gasket is not stop the engine and wait until the cooling system
damaged. Test the cap for the correct pressure. components are cool. Loosen the cooling system
The correct pressure for the cooling system filler pressure cap slowly in order to relieve the
cap is stamped on the face of the cooling system pressure.
filler cap. If the cooling system filler cap does not
retain the correct pressure, install a new cooling 1. Remove the cooling system filler cap slowly to
system filler cap. relieve pressure.
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
M0068760-05 91
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Use a Coolant Conditioner Test Kit in order to check

the concentration of the SCA.

Add the SCA, If Necessary

NOTICE
Do not exceed the recommended amount of supple-
mental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
cooling system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high tempera-
ture components. Excessive supplemental coolant
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water
Illustration 68 g00103639 pump seal wear. Never use both liquid supplemental
Typical filler cap gaskets coolant additive and the spin-on element (if
equipped) at the same time. The use of those addi-
3. Clean the cooling system filler cap and check the tives together could result in supplemental coolant
condition of the filler cap gaskets. Replace the additive concentration exceeding the recommended
maximum.
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks.

i03644948 Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
Cooling System Supplemental components are cool. Loosen the cooling system
Coolant Additive (SCA) - Test/ pressure cap slowly in order to relieve the
pressure.
Add
NOTICE
When any servicing or repair of the engine cooling
system is performed the procedure must be per-
formed with the engine on level ground. This will al-
Cooling system coolant additive contains alkali. low you to accurately check the coolant level. This
To help prevent personal injury, avoid contact will also help in avoiding the risk of introducing an air
with the skin and the eyes. Do not drink cooling lock into the coolant system.
system coolant additive.
1. Slowly loosen the cooling system filler cap in order
to relieve the pressure. Remove the cooling
Test for SCA Concentration system filler cap.
Heavy-Duty Coolant/Antifreeze and SCA Note: Always discard drained fluids according to
local regulations.
NOTICE
Do not exceed the recommended six percent supple- 2. If necessary, drain some coolant from the cooling
mental coolant additive concentration. system into a suitable container in order to allow
space for the extra SCA.
3. Add the correct amount of SCA. Refer to the
Operation and Maintenance Manual, “Refill
Capacities and Recommendations” for more
information on SCA requirements.
92 M0068760-05
Maintenance Section
DEF Filler Screen (Emission Related Component) - Clean

4. Clean the cooling system filler cap and inspect the 2. Using a suitable tool, press the tabs (2) in order to
gasket. If the gasket is damaged, discard the old release the tabs. With the tabs released remove
filler cap and install a new filler cap. If the gasket is the filter screen (3) from DEF tank neck adapter
not damaged, use a suitable pressurizing pump in (4).
order to pressure test the filler cap. The correct
3. The filter screen can be cleaned in clean water and
pressure is stamped on the face of the filler cap. If
dried using compressed air. Refer to this
the filler cap does not retain the correct pressure,
Operation and Maintenance Manual, “General
install a new filler cap.
Hazard Information” for information on using
compressed air.
i07508033
4. If the filter screen cannot be cleaned or the filter
DEF Filler Screen (Emission screen is damaged, then the filter screen must be
Related Component) - Clean replaced.
5. Install filter screen (3) into DEF tank neck adapter
(4). Press filter screen into neck adapter and
ensure that tabs (2) are located correctly. Install
NOTICE
Ensure that the engine is stopped before any servic- cap (1).
ing or repair is performed.
i07508564

DEF Manifold Filters (Emission

Related Component) - Replace

NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.

NOTICE
Care must be taken to ensure that Diesel Exhaust
Fluid (DEF) for the system are contained during per-
formance of inspection, maintenance, testing, adjust-
ing, and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component con-
taining fluids.
Dispose of all fluids according to local regulations
and mandates.

Ensure that the area around the DEF manifold is free

from contamination before any servicing or repair is
performed.
There are two different designs of manifold that could
be installed on your application.

Illustration 69 g03725939
Type 1 Manifold
Typical example
1. Remove the manifold, refer to Disassembly and
1. Ensure that the area around cap on the Diesel Assembly, “Manifold (DEF Heater) - Remove and
Exhaust Fluid (DEF) tank is clean. Remove cap Install” for the correct procedure.
(1).
M0068760-05 93
Maintenance Section
DEF Manifold Filters (Emission Related Component) - Replace

Illustration 70 g03806578

Illustration 71 g03806580

2. Remove band clamp (2) from filter base (1).

3. Remove filter (3) from filter base (1).
94 M0068760-05
Maintenance Section
DEF Manifold Filters (Emission Related Component) - Replace

Illustration 72 g03806581

Illustration 74 g06159487

1. Note the location of clamp (2). The clamp (2) must

be between the marked location (A).
2. Loosen clamp (2) and remove outer filter (3) from
DEF tank header (1) and discard outer filter (3).

Illustration 73 g03806583

4. Remove the suction filter (4) at the bottom of the

header coils by pulling tabs (5). Replace with a
new suction filter.
5. Install new filter by pulling filter over the manifold
coils up to the bottom of the assembled filter base.
6. Ensure that the band clamp is aligned, as shown in
illustration 73 , to the flat section on the filter base.
Tighten the band clamp to 4.5 ± 0.7 N·m
(40 ± 6 lb in) (1). Ensure that the filter does not
bunch when tightening the band clamp.
7. Install the manifold, refer to Disassembly and
Assembly, “Manifold (DEF Heater) - Remove and
Install” for the correct procedure.
Illustration 75 g06159580
Type 2 Manifold
To remove the DEF manifold and the hoses 3. Remove screws (7) and remove retaining plate (6).
connections from the DEF tank, refer to Disassembly 4. Remove DEF filter (5) from pickup tube (4) and
and Assembly, Manifold (DEF Heater) - Remove and
Install. discard the used filter (5).
5. Install new filter (5) onto pickup tube (4).
M0068760-05 95
Maintenance Section
Diesel Exhaust Fluid (Emission Related Component) - Fill

6. Install the retaining plate (6) and install screws (7). Caution should be used when dispensing DEF near
Tighten screws (7) to a torque of 1.1 N·m an engine that has recently been running. Spilling
(9.8 lb in). DEF onto hot components may cause the release of
ammonia vapors. Do not breathe ammonia vapors.
7. Install new outer filter (3) onto DEF tank header Do not clean up any spills with bleach.
(1). Ensure that the clamp (2) is located between
Ensure that the DEF tank is full before starting work.
the location points (A).
1. Before filling the DEF tank, ensure that the DEF
8. Tighten clamp (2) to a torque of 4.5 N·m (40 lb in).
lines have been purged. Purging of the DEF lines
9. Install the DEF tank header, refer to Disassembly will take place, after the engine has stopped. Only
and Assembly, Manifold (DEF Heater) - Remove after purging the DEF lines should the DEF tank
and Install. be filled. For more information on the time taken
for purging the DEF lines, refer to this Operation
i07508011 and Maintenance Manual, “Battery Disconnect
Switch”.
Diesel Exhaust Fluid
2. Ensure the DEF cap (1) and the surrounding area
(Emission Related is clean and free from dirt. Ensure that all
Component) - Fill equipment use in filling the tank is clean and free
from dirt.
3. Remove the DEF cap from the tank.
4. Fill the tank with the required amount of DEF.
Ensure that dirt is not introduced into the tank
during filling. Do not over fill the tank. The DEF will
require room for expansion.
Note: Always fill the DEF tank on level ground. Cold
weather can affect DEF, refer to this Operation, and
Maintenance Manual, “Diesel Exhaust Fluid in cold
Weather” for more information.

5. The opening on the DEF tank (2) is a special

diameter. Ensure that the correct nozzle is used
when filling the DEF tank.
Note: At key on the DEF level gauge will show the
last known DEF level and will transition to the new
DEF level value.

6. Install the DEF cap. Check visually the DEF tank

for leakage.
Illustration 76 g03714036
i07508565
Typical example

Ensure that the correct specification Diesel Exhaust

Diesel Exhaust Fluid Filter
Fluid (DEF) is used. Ensure the cleanliness of the (Emission Related
DEF, refer to this Operation and Maintenance
Manual, “Fluid Recommendations” for more Component) - Replace
information.
Care should be taken when dispensing DEF. Spills
should be cleaned immediately. All surfaces should • Diesel Exhaust Fluid (DEF)
be wiped clean and rinsed with water.
DEF that has been split will crystallize when the
water within the liquid evaporates. Split DEF will
attack paint and metal. If DEF is split, wash the area
with water.
96 M0068760-05
Maintenance Section
Diesel Exhaust Fluid Filter (Emission Related Component) - Replace

Illustration 77 g03332612 Illustration 78 g03332637

Typical Example Typical Example

3. Insert the DEF filter removal tool (4) into the DEF
filter (1) and remove the DEF filter (1).
Personal injury can result from improper han-
dling of chemicals. Note: Avoid twisting the DEF filter (1) upon removal.
Twisting may cause a tear.
Make sure you use all the necessary protective
equipment required to do the job. 4. Clean the area around the filter housing.
Make sure that you read and understand all direc- 5. Lubricate the seals of the new DEF filter (1) with
tions and hazards described on the labels and diesel exhaust fluid or distilled water.
material safety data sheet of any chemical that is
used. 6. Install new DEF filter (1) and rubber cone insert.
Observe all safety precautions recommended by Note: Avoid twisting the DEF filter (1) upon
the chemical manufacturer for handling, storage, installation. Twisting may cause a tear.
and disposal of chemicals.
7. Install the cap (3). Torque the cap to 20 N·m
(177 lb in).
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.

1. Remove the DEF filter cap (3) with a 27mm Bi-Hex

socket.
2. Remove the rubber cone insert (2) from the DEF
filter (1).
M0068760-05 97
Maintenance Section
Diesel Exhaust Fluid Injector (Emission Related Component) - Replace

i07508568 i02151646

Diesel Exhaust Fluid Injector Driven Equipment - Check

(Emission Related
Component) - Replace Refer to the OEM specifications for more information
on the following maintenance recommendations for
the driven equipment:

• Inspection
• Adjustment

• Lubrication
• Other maintenance recommendations
Perform any maintenance for the driven equipment
which is recommended by the OEM.

i06657165

Electronic Unit Injector -

Inspect/Adjust

The Electronic Control Module produces high

Illustration 79 g06043006 voltage. To prevent personal injury make sure the
Typical example Electronic Control Module is not powered and the
unit injector solenoids are disconnected.
1. The Diesel Exhaust Fluid (DEF) injector (2) must
be removed from the body of the aftertreatment
regeneration device (1) and a new DEF injector NOTICE
The camshafts must be correctly timed with the
installed. The DEF lines, coolant lines, and the crankshaft before an adjustment of the unit injector
electrical connection will need to be removed to lash is made. The timing pins must be removed from
replace the DEF injector. For more information the camshafts before the crankshaft is turned or dam-
refer to Disassembly and Assembly, DEF Injector age to the cylinder block will be the result.
and Mounting Remove and Install.
The operation of Perkins engines with improper
adjustments of the electronic unit injector can reduce
i07508573 engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
Diesel Particulate Filter component life.
(Emission Related Adjust the electronic unit injector at the same interval
Component) - Clean as the valve lash adjustment.
Refer to Systems Operation Testing and Adjusting,
Electronic Unit Injector - Adjust for more information,
Consult your Perkins distributor when the diesel or contact your Perkins distributor.
particulate filter needs to be cleaned for the options
that are available.
The ash monitoring system within the electric control
module will require a reset.
98 M0068760-05
Maintenance Section
Engine - Clean

i07819515 Aftertreatment
Engine - Clean During the engine cleaning process, ensure that
water or cleaning fluids cannot enter the
aftertreatment system. If cleaning fluids enters the
aftertreatment system, damage could occur.

i07003542
Personal injury or death can result from high
voltage. Engine Air Cleaner Element -
Moisture can create paths of electrical Replace
conductivity.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “ DO NOTICE
NOT OPERATE”” . Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements
NOTICE with damaged pleats, gaskets or seals. Dirt entering
Accumulated grease and oil on an engine is a fire the engine causes premature wear and damage to
hazard. Keep the engine clean. Remove debris and engine components. Air cleaner elements help to pre-
fluid spills whenever a significant quantity accumu- vent airborne debris from entering the air inlet.
lates on the engine.
Periodic cleaning of the engine is recommended. NOTICE
Steam cleaning the engine will remove accumulated Never service the air cleaner element with the engine
oil and grease. A clean engine provides the following running since this will allow dirt to enter the engine.
benefits:
Ensure that the engine cannot start before any
• Easy detection of fluid leaks service or repair is performed.
• Maximum heat transfer characteristics
Servicing the Air Cleaner Element
• Ease of maintenance
Note: The air filter system may not have been
Note: Caution must be used to prevent electrical provided by Perkins. The procedure that follows is for
components from being damaged by excessive water a typical air filter system. Refer to the OEM
when the engine is cleaned. Pressure washers and information for the correct procedure.
steam cleaners should not be directed at any
electrical connectors or the junction of cables into the If the air cleaner element becomes plugged, the air
rear of the connectors. Avoid electrical components can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
such as the alternator, the starter, and the ECM.
engine wear. Refer to the OEM information for the
Protect the fuel injection pump from fluids to wash the correct air cleaner elements for your application.
engine.
• Check the air cleaner service indicator daily.
Ensure that care is taken that the safety labels,
emission label, and all other information labels are • Check the pre-cleaner (if equipped) and the dust
not removed during engine cleaning.
bowl daily for accumulation of dirt and debris.
Remove any dirt and debris, as needed.

• Operating in dirty conditions may require more

frequent service of the air cleaner element.
M0068760-05 99
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Replace the dirty air cleaner elements with new air 3. Remove the primary air filter element (2) and
cleaner elements. Before installation, the air cleaner remove the secondary air filter element (not
elements should be thoroughly checked for tears shown) from air cleaner body (1). Ensure that the
and/or holes in the filter material. Inspect the gasket
or the seal of the air cleaner element for damage. inner body of the air cleaner is clean and free from
Maintain a supply of suitable air cleaner elements for dirt. Ensure that the inner of the air cleaner cover ,
replacement purposes. (3) is clean and free from dirt.
4. Install a new secondary air filter element (not
Dual Element Air Cleaner shown). Install a new primary air filter element (2)
The dual element air cleaner contains a primary air and install end cover (3). Ensure that the clips (4)
cleaner element and a secondary air cleaner are located securely.
element.
i06103548
When the engine is operating in environments that
are dusty or dirty, air cleaner elements may require
more frequent replacement. Engine Air Cleaner Service
If equipped, perform maintenance on the pre-cleaner
Indicator - Inspect
or the dust bowl before performing maintenance on (If Equipped)
the air filter elements.

Some engines may be equipped with a different

service indicator.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before and after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the clean
side of the air cleaner housing or in a remote
location.

Illustration 80 g06043462
Typical example

Note: Do not allow dirt to enter the air system during

replacement of the air filter elements.

1. Clean the outer casing of the air cleaner before

removing the end cover (3).

Note: Before removal, check the orientation of the Illustration 81 g00103777

end cover (3). Some air cleaners the end cover must
Typical service indicator
be installed in the correctly aligned position.
Observe the service indicator. The air cleaner
2. Release the clips (4) and remove the end cover (3) element should be cleaned or the air cleaner element
from air cleaner body (1). should be replaced when one of the following
conditions occur:
• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

100 M0068760-05
Maintenance Section
Engine Mounts - Inspect

Test the Service Indicator i06606939

Service indicators are important instruments. Engine Oil Level - Check

• Check for ease of resetting. The service indicator
should reset in less than three pushes.

• Check the movement of the service indicator core

when the engine is run at full load speed. The core Hot oil and hot components can cause personal
should latch approximately at the greatest vacuum injury. Do not allow hot oil or hot components to
that is attained. contact the skin.
If the service indicator does not reset easily, or if the
core does not latch at the greatest vacuum, the
service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be plugged.
If necessary, replace the service indicator more
frequently in environments that are severely dusty.
Replace the service indicator annually regardless of
the operating conditions. Replace the service
indicator when the engine is overhauled, and
whenever major engine components are replaced.

Note: When a new service indicator is installed,

excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque of
2 N·m (18 lb in).

i07819538

Engine Mounts - Inspect

Note: The engine mounts may not have been

supplied by Perkins. Refer to the Original Equipment
Manufacturer (OEM) information for further details on
the engine mounts and the correct bolt torque.
Inspect the engine mounts for deterioration and for
correct bolt torque. Excessive engine vibration can Illustration 82 g06043530
be caused by the following conditions:
Typical example
• Incorrect mounting of the engine (1) Oil level gauge (Dipstick)
(2) Oil filler cap
• Deterioration of the engine mounts
• Loose engine mounts
Any engine mount that shows deterioration should be
replaced. Refer to the OEM information for the
recommended torques.
When the engine mounts are supplied by Perkins the
maintenance procedure will be supplied in the
Disassembly and Assembly manual for your engine. Illustration 83 g00110310
Partial view of the oil level gauge
(Y) “ADD” mark
(X) “FULL” mark
M0068760-05 101
Maintenance Section
Engine Oil Sample - Obtain

Perkins recommends using a sampling valve in order

NOTICE to obtain oil samples. The quality and the consistency
Perform this maintenance with the engine stopped.
of the samples are better when a sampling valve is
used. The location of the sampling valve allows oil
that is flowing under pressure to be obtained during
NOTICE normal engine operation.
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge
(dipstick). Obtain the Sample and the
An overfull crankcase can cause the crankshaft to dip
Analysis
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil Hot oil and hot components can cause personal
pressure, inadequate cooling, oil blowing out of the injury. Do not allow hot oil or hot components to
crankcase breathers and excessive oil consumption. contact the skin.
Excessive oil consumption will cause deposits to form In order to help obtain the most accurate analysis,
on the pistons and in the combustion chamber. De- record the following information before an oil sample
posits in the combustion chamber lead to the follow- is taken:
ing problems: guttering of the valves, packing of
carbon under the piston rings and wear of the cylin- • The date of the sample
der liner.
If the oil level is above the “FULL” mark on the oil lev- • Engine model
el gauge, drain some of the oil immediately.
• Engine number

1. Remove the oil level gauge to check engine oil • Service hours on the engine
level. Maintain the oil level between the “ADD”
• The number of hours that have accumulated since
mark (Y) and the “FULL” mark (X) on the oil level the last oil change
gauge (1). Do not fill the crankcase above “FULL”
mark (X). • The amount of oil that has been added since the
last oil change
2. If engine oil is required, remove oil filler cap to add
engine oil. Ensure that the container for the sample is clean and
dry. Also ensure that the container for the sample is
3. To choose the correct type of oil for this engine, clearly labelled.
refer to this Operation and Maintenance Manual,
“Fluid Recommendations”. To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, well mixed oil
4. Clean the oil filler cap and install the oil filler cap. sample.
5. Record the amount of oil that is added. For the To avoid contamination of the oil samples, the tools
next oil sample and analysis, include the total and the supplies that are used for obtaining oil
amount of oil that has been added since the samples must be clean.
previous sample. Recording this information helps
to provide the most accurate oil analysis.

i01907674

Engine Oil Sample - Obtain

The condition of the engine lubricating oil may be

checked at regular intervals as part of a preventive
maintenance program. Perkins include an oil
sampling valve as an option. The oil sampling valve
(if equipped) is included in order to regularly sample
the engine lubricating oil. The oil sampling valve is
positioned on the oil filter head or the oil sampling
valve is positioned on the cylinder block.
102 M0068760-05
Maintenance Section
Engine Oil and Filter - Change

The sample can be checked for the following: the

quality of the oil, the existence of any coolant in the NOTICE
Keep all parts clean from contaminants.
oil, the existence of any ferrous metal particles in the
oil and the existence of any nonferrous metal Contaminants may cause rapid wear and shortened
particles in the oil. component life.

i07014109 Do not drain the engine lubricating oil when the

engine is cold. As the engine lubricating oil cools,
Engine Oil and Filter - Change suspended waste particles settle on the bottom of the
oil pan. The waste particles are not removed with
draining cold oil. Drain the oil pan with the engine
stopped. Drain the oil pan with the oil warm. This
draining method allows the waste particles that are
suspended in the oil to be drained properly.
Hot oil and hot components can cause personal Failure to follow this recommended procedure will
injury. Do not allow hot oil or hot components to cause the waste particles to be recirculated through
contact the skin. the engine lubrication system with the new oil.
Note: Ensure that the vessel that will be used is large
Oil and Filter Change Intervals enough to collect the waste oil.
After the engine has been run at the normal
The standard engine oil and filter change period is operating temperature, stop the engine. Use one of
500 hours. There are several other factors that can the following methods to drain the engine oil pan:
alter the standard engine oil and filter change of 500
hours.
• If the engine is equipped with a drain valve, turn
• If the engine is using engine oil analysis to the drain valve knob counterclockwise to drain the
determine oil and filter change period. oil. After the oil has drained, turn the drain valve
knob clockwise to close the drain valve.
• The engine is working in a severe service
environment/Load Factor • If the engine is not equipped with a drain valve,
remove the oil drain plug to allow the oil to drain.
• Infrequent operation of the engine
After the oil has drained, the oil drain plug should be
Refer to this Operation and Maintenance Manual, cleaned. If necessary, replace the O ring seal and
“Severe Service Application” for more information on install the plug. Tighten the drain plug to 35 N·m
reducing the engine oil and filter change period. For (26 lb ft).
severe service applications the recommended oil and
filter change period is 250 hours. Replace the Oil Filter
If the engine is operated in severe service conditions,
Perkins recommends the use of engine oil sampling. NOTICE
Refer to this Operation and Maintenance Manual, Perkins oil filters are manufactured to Perkins specifi-
Engine Oil sample - Obtain for more information. cations. Use of an oil filter that is not recommended
by Perkins could result in severe damage to the en-
If the engine is operated infrequently less than 500 gine bearings, and crankshaft. As a result of the larg-
hours in a 12-month period, then the engine oil and er waste particles from unfiltered oil entering the
filter change should be conducted yearly. engine lubricating system. Only use oil filters recom-
mended by Perkins.
Drain the Engine Lubricating Oil
1. Remove the oil filter with a suitable tool.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
M0068760-05 103
Maintenance Section
Engine Valve Lash - Check

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

Maintain the oil level between the ADD and FULL
marks on the side of the oil level gauge.

i07512811

Engine Valve Lash - Check

Ensure that the engine cannot be started while

this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before
measuring/adjusting valve lash clearance.

Illustration 84 g06043562 NOTICE

Typical example Only qualified service personel should perform this
maintenance. Refer to the Service Manual or your au-
thorized Perkins dealer or your Perkins distributor for
2. Clean sealing surface (1).
the complete valve lash adjustment procedure.
3. Apply clean engine oil to O ring seal (2) for the new
Operation of Perkins engines with incorrect valve
oil filter (3). lash can reduce engine efficiency, and also reduce
engine component life.
NOTICE
Do not fill the oil filter with oil before installing. This oil The initial valve lash adjustment on new engines,
would not be filtered and could be contaminated. rebuilt engines, or remanufactured engines is
Contaminated oil can cause accelerated wear to en- recommended only on engine ratings 522 kW
gine components.
(700 hp) and greater. The adjustment is necessary
due to the initial wear of the valve train components
4. Install the new oil filter (3). Spin on the oil filter until and to the seating of the valve train components.
the O ring contacts the sealing surface (1). Then This maintenance is recommended as part of a
rotate the oil filter 1 full turn. Remove the container lubrication and preventive maintenance schedule to
and disposal of the waste oil in accordance with help provide maximum engine life. For engine ratings
local regulations. less than 522 kW (700 hp), the initial valve lash
adjustment is not necessary.
Fill the Oil Pan Note: All engine ratings must have the engine valve
lash performed at 2500 hours.
1. Remove the oil filler cap. Refer to this Operation
and Maintenance Manual, “Fluid Ensure that the engine is stopped before measuring
Recommendations” for more information on the valve lash. To obtain an accurate measurement,
suitable oils. Fill the oil pan with the correct allow the valves to cool before this maintenance is
performed.
amount of new engine lubricating oil. Refer to this
Operation and Maintenance Manual, “Refill During valve adjustment, visibly inspect the valve
Capacities” for more information on refill train of wear or damage.
capacities.
Refer to Systems Operation, Testing and Adjusting,
2. Start the engine and run the engine at LOW IDLE “Engine Valve Lash - Inspect/Adjust” for more
for 2 minutes. Perform this procedure to ensure information.
that the lubrication system has oil and that the oil
filters are filled. Inspect the oil filter for oil leaks.
3. Stop the engine and allow the oil to drain back to
the oil pan for a minimum of 10 minutes.
104 M0068760-05
Maintenance Section
Fuel System - Prime

i06827467 The fuel system can also be primed by using the key
switch. Turn the key to the ON position for 2 minutes.
Fuel System - Prime After 2 minutes the fuel system should be primed. If
necessary, by cycling the key switch the system will
prime again for 2 minutes.

NOTICE i06614133
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that Fuel System Primary Filter
will be disconnected. Fit a suitable cover over any
disconnected fuel system components. (Water Separator) Element -
Replace

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected fuel system components.

NOTICE
Do not fill fuel filters with fuel before installing
them. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause ac-
Illustration 85 g06046130 celerated wear to fuel system parts. The fuel sys-
(1) Fuel priming pump tem should be primed prior to starting the engine.
(2) Fuel priming switch
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
1. The fuel system can be primed from the keyswitch
to fail. If the fuel has been contaminated with water,
or from a remote mounted switch (2). the element should be changed before the regularly
scheduled interval.
2. Turn the fuel priming switch (2) to the ON position.
Hold the fuel priming switch in the ON position for The primary filter/water separator also provides
2 minutes. If the fuel system is being primed from filtration to help extend the life of the secondary fuel
empty, then turn the switch off and then on again filter. The element should be changed regularly. If a
for 2 minutes. vacuum gauge is installed, the primary filter/water
separator should be changed at 50 kPa to 70 kPa
3. After 2 minutes the fuel system should be primed (7.25 psi to 10.15 psi).
and the engine ready to start.
4. Start the engine, refer to this Operation and
Maintenance Manual, Starting the Engine or refer
to the OEM for instructions on starting the engine.
5. If the engine starts and the engine runs rough or
the engine misfires, operate at low idle until the
engine is running smoothly. If the engine cannot
be started, or if the engine continues to misfire or
smoke, repeat Step 2.
M0068760-05 105
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

i06616051

Fuel System Primary Filter/

Water Separator - Drain

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected fuel system components.
Illustration 86 g06046186

1. Close the main fuel supply valve.

2. Place a suitable container below the primary fuel
filter to catch any fluid that may spill. Clean any
split fluid.
3. Clean the outside of the primary fuel filter.
4. Using a suitable tool, remove the spin on filter (4)
from filter base (1). Discard old filter element.
5. Ensure the seal surface (2) is clean. Apply clean
diesel fuel to the O ring seal (3) on the new spin on
filter.
6. Install the new spin on filter to the filter base (1).
Spin on the filter until the O ring seal (3) contact
the sealing surface (2). Then, rotate the spin on
filter ¾ of a full turn.
7. The secondary fuel filter should be replaced when
the primary fuel filter is replaced. For more
Illustration 87 g03807817
information refer to this Operation and
Maintenance Manual, “Fuel System Secondary Typical example
Filter - Replace”.
1. Ensure that the engine is stopped. Open drain (1).
8. Dispose of the fluid and old filter in accordance The drain is a self-ventilated drain. Catch the
with local regulations. draining water in a suitable container. Dispose of
the water properly.
2. Close drain (3).

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the
fuel system.
106 M0068760-05
Maintenance Section
Fuel System Secondary Filter - Replace

i06605835

Fuel System Secondary Filter -

Replace

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected fuel system components.
Illustration 88 g06042986

NOTICE Typical example

Ensure that the engine is stopped before any servic-
ing or repair is performed. Note: The fuel system has two secondary filters, both
must be replaced.
Refer to Systems Operation, Testing, and
Adjusting, “Cleanliness of Fuel System 3. The residual fuel pressure in the fuel system may
Components” for detailed information on the need relieving. Wait from 1 minute to 5 minutes
standards of cleanliness that must be observed
during ALL work on the fuel system. until the fuel pressure has lowered.

1. Turn the fuel supply valve (if equipped) OFF before 4. Use a suitable tool remove the spin on fuel filter
performing this maintenance. (3).

2. Place a suitable container under the fuel filters to 5. Ensure the sealing surface (1) is clean. Lubricate
catch any fuel that might spill. Clean up any spilled the O ring seal (2) on the new spin on filter with
fuel. Clean the outside body of both fuel filters. clean diesel fuel.
6. Install the new spin on filter (3) to the filter base.
Spin on the filter until the O ring seal (2) contact
the sealing surface (1). Then, rotate the spin on
filter 1 full turn.
7. Replace the other secondary fuel filter, refer to
step 2 through to step 6.
8. Turn on the fuel supply valve. Dispose of the fluid
and old filters in accordance with local regulations.
9. The primary fuel filter the secondary fuel filter must
be replaced at the same time. Refer to the
Operation and Maintenance Manual, “Fuel System
Primary Filter (Water Separator) Element -
Replace”. The engine will need to be purged of air.
With primary and secondary fuel filters replace,
Refer to Operation and Maintenance Manual,
“Fuel System Prime”.
M0068760-05 107
Maintenance Section
Fuel Tank Water and Sediment - Drain

i02348492 Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If the
- Drain engine is equipped with this system, regular
maintenance of the fuel system filter is important.

Fuel Storage Tanks

NOTICE
Care must be taken to ensure that fluids are con- Drain the water and the sediment from the fuel
tained during performance of inspection, mainte- storage tank at the following intervals:
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain- • Weekly
ers before opening any compartment or disassem-
bling any component containing fluids. • Service intervals
Dispose of all fluids according to local regulations • Refill of the tank
and mandates.
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
Fuel Tank tank.
If a bulk storage tank has been refilled or moved
Fuel quality is critical to the performance and to the recently, allow adequate time for the sediment to
service life of the engine. Water in the fuel can cause settle before filling the engine fuel tank. Internal
excessive wear to the fuel system. baffles in the bulk storage tank will also help trap
Water can be introduced into the fuel tank when the sediment. Filtering fuel that is pumped from the
fuel tank is being filled. storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
Condensation occurs during the heating and cooling
of fuel. The condensation occurs as the fuel passes i03965989
through the fuel system and the fuel returns to the
fuel tank. This causes water to accumulate in fuel
tanks. Draining the fuel tank regularly and obtaining
Grounding Stud - Inspect/
fuel from reliable sources can help to eliminate water Clean/Tighten
in the fuel.

Drain the Water and the Sediment

Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Open the drain valve on the bottom of the fuel tank in
order to drain the water and the sediment. Close the
drain valve.
Check the fuel daily. Allow five minutes after the fuel
tank has been filled before draining water and
sediment from the fuel tank.
Fill the fuel tank after operating the engine in order to
drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may Illustration 89 g01376112
overflow.
The grounding stud is located on the upper left corner
of the engine control module.

Inspect the OEM harness for good connections.

Inspect the condition of the OEM harness.
108 M0068760-05
Maintenance Section
Hoses and Clamps - Inspect/Replace

The grounding stud must have a wire ground to the A constant torque hose clamp can be used in place
battery. Tighten the grounding stud at every oil of any standard hose clamp. Ensure that the constant
change. Ground wires and straps should be torque hose clamp is the same size as the standard
combined at engine grounds. All grounds should be clamp.
tight and free of corrosion.
Due to extreme temperature changes, the hose will
• Clean the grounding stud and the terminals for the harden. Hardening of the hoses will cause hose
ground strap with a clean cloth. clamps to loosen. This hardening can result in leaks.
A constant torque hose clamp will help to prevent
• If the connections are corroded, clean the loose hose clamps.
connections with a solution of baking soda and
water. Each installation application can be different. The
differences depend on the following factors:
• Keep the grounding stud and the strap clean and
coated with MPGM grease or petroleum jelly. • Type of hose

• Type of fitting material

i06103230
• Anticipated expansion and contraction of the hose
Hoses and Clamps - Inspect/
• Anticipated expansion and contraction of the
Replace fittings

Replace the Hoses and the Clamps

Refer to the OEM information for further information
on removing and replacing fuel hoses (if equipped).
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel The following text describes a typical method of
spray may cause a fire hazard. Failure to follow replacing coolant hoses. Refer to the OEM
these inspection, maintenance and service in- information for further information on the coolant
structions may cause personal injury or death. system and the hoses for the coolant system.
If you inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Inspect all hoses for leaks that are caused by the stop the engine and wait until the cooling system
following conditions: components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
• Cracking pressure.

• Softness
1. Stop the engine. Allow the engine to cool.
• Loose clamps
2. Loosen the cooling system filler cap slowly in order
Replace hoses that are cracked or soft. Tighten any to relieve any pressure. Remove the cooling
loose clamps. system filler cap.
Check for the following conditions: Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
• End fittings that are damaged or leaking
3. Drain the coolant from the cooling system to a
• Outer covering that is chafed or cut
level that is below the hose that is being replaced.
• Exposed wire that is used for reinforcement 4. Remove the hose clamps.
• Outer covering that is ballooning locally 5. Disconnect the old hose.
• Flexible part of the hose that is kinked or crushed 6. Replace the old hose with a new hose.

• Armoring that is embedded in the outer covering 7. Install the hose clamps with a torque wrench.

Note: For the correct coolant, see this Operation and

Maintenance Manual, “Fluid Recommendations”.
M0068760-05 109
Maintenance Section
Overhaul Considerations

8. Refill the cooling system. Refer to the OEM Pressurized air is the preferred method for removing
information for further information on refilling the loose debris. Direct the air in the opposite direction of
cooling system. the air flow. Hold the nozzle approximately 6 mm
(0.25 inch) away from the fins. Slowly move the air
9. Clean the cooling system filler cap. Inspect the nozzle in a direction that is parallel with the tubes.
cooling system filler caps seals. Replace the This movement will remove debris that is between
the tubes.
cooling system filler cap if the seals are damaged.
Install the cooling system filler cap. Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
10. Start the engine. Inspect the cooling system for must be less than 275 kPa (40 psi). Use pressurized
leaks. water in order to soften mud. Clean the core from
both sides.
Fuel System Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
The fuel system is split into two different sections, with detergent and hot water. Thoroughly rinse the
high pressure, and low pressure. Ensure that the fuel core with clean water.
pressure has been purged before any parts are
removed loosened or replaced. After cleaning, start the engine and accelerate the
engine to high idle rpm. This procedure will help in
Check that connections and hoses are secure, check the removal of debris and drying of the core. Stop the
for leaks. If parts are to be removed or tightened, engine. Use a light bulb behind the core in order to
refer to the Disassembly and Assembly manual for inspect the core for cleanliness. Repeat the cleaning,
more information. if necessary.

i05971077 Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition:
Overhaul Considerations welds, mounting brackets, air lines, connections,
clamps and seals. Make repairs, if necessary.

i02568202
For an overhaul solution, contact your Perkins
distributor.
Starting Motor - Inspect
i04020194

Radiator - Clean Perkins recommends a scheduled inspection of the

starting motor. If the starting motor fails, the engine
may not start in an emergency situation.

Note: Adjust the frequency of cleaning according to Check the starting motor for proper operation. Check
the effects of the operating environment. the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
Inspect the radiator for these items: damaged fins, information on the checking procedure and for
corrosion, dirt, grease, insects, leaves, oil and other specifications or consult your Perkins distributors for
debris. Clean the radiator, if necessary. assistance.

i06101140

Personal injury can result from air pressure. Walk-Around Inspection

Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing. Inspect the Engine for Leaks and
The maximum air pressure for cleaning purposes
for Loose Connections
must be reduced to 205 kPa (30 psi) when the air A walk-around inspection should only take a few
nozzle is deadheaded. minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
110 M0068760-05
Maintenance Section
Walk-Around Inspection

For maximum engine service life, make a thorough Belts for multiple groove pulleys must be replaced as
inspection of the engine compartment before starting matched sets. If only one belt is replaced, the belt will
the engine. Look for items such as oil leaks or carry more load than the belts that are not replaced.
coolant leaks, loose bolts, worn belts, loose The older belts are stretched. The additional load on
connections, and trash buildup. Make repairs, as the new belt could cause the belt to break.
needed:
• Drain the water and the sediment from fuel tanks
• The guards must be in the proper place. Repair on a daily basis in order to ensure that only clean
damaged guards or replace missing guards. fuel enters the fuel system.
• Wipe all caps and plugs before the engine is • Inspect the wiring and the wiring harnesses for
serviced in order to reduce the chance of system loose connections and for worn wires or frayed
contamination. wires.

• Inspect the ground strap for a good connection

NOTICE
For any type of leak (coolant, lube, or fuel) clean up and for good condition.
the fluid. If leaking is observed, find the source and
correct the leak. If leaking is suspected, check the flu- • Inspect the ECM to the cylinder head ground strap
id levels more often than recommended until the leak for a good connection and for good condition.
is found or fixed, or until the suspicion of a leak is
proved to be unwarranted. • Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte
NOTICE level of the batteries, unless the engine is
Accumulated grease and/or oil on an engine or deck equipped with a maintenance free battery.
is a fire hazard. Remove this debris with steam clean-
ing or high pressure water. • Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that
cannot be calibrated.
• Ensure that the cooling lines are properly clamped
and that the cooling lines are tight. Check for Aftertreatment System
leaks. Check the condition of all pipes.
Check the condition of the coolant lines, Diesel
• Inspect the water pumps for coolant leaks. Exhaust Fluid (DEF) lines, and electrical
connections. Check that all clamps, clips, and tie-
Note: The water pump seal is lubricated by coolant in wraps are secure and in good condition. Check that
the cooling system. It is normal for a small amount of the DEF filler cap is secure and that the cap is clean
leakage to occur as the engine cools down and the and free from dirt.
parts contract.
Check the level of DEF in the tank is adequate for
Excessive coolant leakage may indicate the need to operational purpose, if necessary fill the DEF tank.
replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/
or seals, refer to the Service Manual for the engine or
consult your Perkins distributor .
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters, and the valve cover.
• Inspect the fuel system for leaks. Look for loose
fuel line clamps or for loose fuel line tie-wraps.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, and wiring harnesses.

• Inspect the alternator belt and the accessory drive

belts for cracks, breaks, or other damage.
M0068760-05 111
Warranty Section
Warranty Information

Warranty Section 3. New non-road diesel engines installed in

construction machines conforming to theSouth
Korean regulations for construction machines
Warranty Information manufactured after January 1, 2015, and operated
and serviced inSouth Korea, including all parts of
their emission control systems (“emission related
i07304835 components”), are:
Emissions Warranty a. Designed, built, and equipped so as to conform,
at the time of sale, with applicable emission
Information standards prescribed in the Enforcement Rule
of the Clean Air Conservation Act promulgated
by South Korea MOE.
The certifying engine manufacturer warrants to the
ultimate purchaser and each subsequent purchaser b. Free from defects in materials and
that: workmanship in emission-related components
1. New non-road diesel engines and stationary diesel that can cause the engine to fail to conform to
engines less than 10 L per cylinder (including Tier applicable emission standards for the warranty
1 and Tier 2 marine engines < 37 kW, but period.
excluding locomotive and other marine engines) The aftertreatment system can be expected to
operated and serviced in the United States and function properly for the lifetime of the engine
Canada, including all parts of their emission (emissions durability period) subject to prescribed
control systems (“emission-related components”), maintenance requirements being followed.
are:
For a detailed explanation of the Emission Control
a. Designed, built, and equipped so as to conform, Warranty, contact your authorized Perkins dealer or
at the time of sale, with applicable emission your authorized Perkins distributor.
standards prescribed by the United States
Environmental Protection Agency (EPA) by way
of regulation.
b. Free from defects in materials and
workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission-related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).
b. Free from defects in materials and
workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.
112 M0068760-05
Reference Information Section
Reference Materials

Reference Information www.perkins.com

Section NOTICE
Dependant upon engine type and application.

Reference Materials i06103116

i07677995 Decommissioning and

Reference Material Disposal
(Extended Service Contract)
When the product is removed from service, local
regulations for the product decommissioning will
Extended Service Contracts - purchased in minutes, vary. Disposal of the product will vary with local
protected for years. regulations. Consult the nearest Perkins distributor
for additional information.
Extended Service Contracts (ESC) protect you from
the stress that unexpected repair work brings to your i05204672
life by covering the cost of getting your engine up and
running again. Unlike other extended warranties,
Perkins Platinum ESC protects you against all Maintenance Records
component part failures.
Purchase peace of mind from only £0.03 / $0.05 / Perkins recommends the retention of accurate
euro 0.04 a day and let an ESC make your dreams a maintenance records. Accurate maintenance records
reality. can be used for the following purposes:

Why buy an Extended Service Contract? • Determine operating costs.

1. No surprises - total protection from unexpected • Establish maintenance schedules for other
repair cost (parts, labor, and travel). engines that are operated in the same
environment.
2. Enjoy longer lasting product support from Perkins
global network. • Show compliance with the required maintenance
practices and maintenance intervals.
3. Genuine Perkins parts ensure continued engine
performance. Maintenance records can be used for various other
business decisions that are related to engine
4. Highly trained technicians carry out all repairs. maintenance.
5. Transferable coverage should you sell your Maintenance records are a key element of a
machine. maintenance program that is correctly managed.
Accurate maintenance records can help your Perkins
Flexible coverage provides the right level of dealer to fine-tune the recommended maintenance
protection for your Perkins Engine. Coverage can be intervals in order to meet the specific operating
extended to 2 years/ 1,000 hours right up to 10 year/ situation. This should result in a lower engine
40,000 operating cost.
You can buy an ESC at any time during standard Records should be kept for the following items:
warranty - even the last day!
Fuel Consumption – A record of fuel consumption is
Each Perkins Distributor has highly trained and essential in order to determine when the load
experienced Perkins Product Support Service sensitive components should be inspected or
Technicians. The Support Service is equipped, and repaired. Fuel consumption also determines overhaul
available around the clock to get your engine running intervals.
again with the minimum of downtime. Buying an ESC
means that you get all this for free. Service Hours – A record of service hours is
essential to determine when the speed sensitive
To purchase an Extended Service Contract, is quick components should be inspected or repaired.
and simple! Contact your local Perkins Distributor
now and the distributor can provide you with a quote Documents – These items should be easy to obtain,
in minutes. You can locate your nearest Perkins and these items should be kept in the engine history
Distributor by visiting: file. All of the documents should show this
information: date, service hours, fuel consumption,
M0068760-05 113
Reference Information Section
Maintenance Log

unit number and engine serial number. The following

types of documents should be kept as proof of
maintenance or repair for warranty:

Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owners repair costs

• Owners receipts
• Maintenance log

i05204675

Maintenance Log

Table 19
Engine Model Customer Identifier

Serial Number Arrangement Number

Service Quantity Of
Service Item Date Authorization
Hours Fuel

(continued)
114 M0068760-05
Reference Information Section
Maintenance Log

(Table 19, contd)

M0068760-05 115
Index Section

Index
A System Configuration Parameters .............. 42
Cooling System Coolant (DEAC) - Change .... 87
Additional Messages ......................................... 7
Drain ............................................................ 88
After Starting Engine ....................................... 49
Fill ................................................................ 88
Extended Idle at Cold Ambient
Flush ............................................................ 88
Temperature............................................... 50
Cooling System Coolant (ELC) - Change ....... 89
After Stopping Engine ..................................... 56
Drain ............................................................ 89
Air Compressor - Check (If Equipped) ............ 84
Fill ................................................................ 90
Air Shutoff - Test .............................................. 84
Flush ............................................................ 89
Air Tank Moisture and Sediment - Drain (If
Cooling System Coolant Extender (ELC) -
Equipped) ...................................................... 85
Add ................................................................ 90
ARD Spark Plug (Emission Related
Cooling System Coolant Level - Check........... 90
Component) - Clean ...................................... 83
Cooling System Supplemental Coolant
Installing the Spark Plug .............................. 83
Additive (SCA) - Test/Add.............................. 91
Removing the Spark Plug............................ 83
Add the SCA, If Necessary .......................... 91
Test for SCA Concentration ......................... 91
B Crushing Prevention and Cutting Prevention.. 14
Battery - Recycle ............................................. 85
Battery - Replace............................................. 85 D
Battery Disconnect Switch (If Equipped)......... 36
Decommissioning and Disposal.....................112
Battery Electrolyte Level - Check .................... 86
DEF Filler Screen (Emission Related
Battery or Battery Cable - Disconnect............. 86
Component) - Clean ...................................... 92
Before Starting Engine .............................. 14, 46
DEF Manifold Filters (Emission Related
Belts - Inspect/Adjust/Replace ........................ 87
Component) - Replace .................................. 92
Adjust ........................................................... 87
Type 1 Manifold ........................................... 92
Inspect ......................................................... 87
Type 2 Manifold ........................................... 94
Replace........................................................ 87
Diesel Exhaust Fluid (Emission Related
Burn Prevention................................................11
Component) - Fill ........................................... 95
Batteries........................................................11
Diesel Exhaust Fluid Filter (Emission
Coolant .........................................................11
Related Component) - Replace..................... 95
Diesel Fuel ....................................................11
Diesel Exhaust Fluid Injector (Emission
Engine and Aftertreatment System ..............11
Related Component) - Replace..................... 97
Oils................................................................11
Diesel Particulate Filter (Emission Related
Component) - Clean ...................................... 97
C Diesel Particulate Filter Regeneration ............ 51
Cold Weather Operation ................................. 57 Carbon Dioxide (CO2) Emissions
Extended Idle at Cold Ambient Statement................................................... 53
Temperature............................................... 58 Modes of Regeneration ............................... 52
Hints for Cold-Weather Operation ............... 57 Regeneration ............................................... 51
Idling the Engine .......................................... 58 Regeneration Indicators .............................. 51
Insulated Heater Lines................................. 58 Regeneration Switch ................................... 51
Recommendations for Coolant Warm Up.... 58 Regeneration System Warning Indicators... 52
Recommendations for the Coolant.............. 57 Regeneration Triggers................................. 52
Viscosity of the Engine Lubrication Oil ........ 57 Driven Equipment - Check .............................. 97
Cold Weather Starting ..................................... 48
Ether Injection System (If Equipped)........... 48 E
Configuration Parameters ............................... 42
Electrical System............................................. 15
Customer Specified Parameters ................. 43
116 M0068760-05
Index Section

Grounding Practices .................................... 15 General Information..................................... 69

Electronic Unit Injector - Inspect/Adjust .......... 97 Foreword ........................................................... 4
Emissions Certification Film ............................ 24 California Proposition 65 Warning ................. 4
Emissions Warranty Information .................... 111 Literature Information .................................... 4
Engaging the Driven Equipment ..................... 53 Maintenance .................................................. 4
Engine - Clean................................................. 98 Maintenance Intervals ................................... 5
Aftertreatment.............................................. 98 Operation ....................................................... 4
Engine Air Cleaner Element - Replace ........... 98 Overhaul ........................................................ 5
Dual Element Air Cleaner ............................ 99 Safety............................................................. 4
Servicing the Air Cleaner Element .............. 98 Fuel and the Effect from Cold Weather ........... 59
Engine Air Cleaner Service Indicator - Fuel Conservation Practices ........................... 54
Inspect (If Equipped) ..................................... 99 Fuel Related Components in Cold Weather ... 59
Test the Service Indicator .......................... 100 Fuel Heaters ................................................ 59
Engine Diagnostics ......................................... 42 Fuel Tanks ................................................... 59
Engine Electronics........................................... 16 Fuel System - Prime...................................... 104
Engine Mounts - Inspect................................ 100 Fuel System Primary Filter (Water
Engine Oil and Filter - Change ...................... 102 Separator) Element - Replace..................... 104
Drain the Engine Lubricating Oil................ 102 Fuel System Primary Filter/Water
Fill the Oil Pan............................................ 103 Separator - Drain ......................................... 105
Oil and Filter Change Intervals .................. 102 Fuel System Secondary Filter - Replace ...... 106
Engine Oil Level - Check............................... 100 Fuel Tank Water and Sediment - Drain ......... 107
Engine Oil Sample - Obtain........................... 101 Drain the Water and the Sediment ............ 107
Obtain the Sample and the Analysis ......... 101 Fuel Storage Tanks.................................... 107
Engine Operation ............................................ 51 Fuel Tank ................................................... 107
Engine Operation and the Aftertreatment
System ....................................................... 51 G
Engine Starting.......................................... 15, 46
Engine Stopping ........................................ 15, 55 General Hazard Information.............................. 7
Engine Valve Lash - Check ........................... 103 Containing Fluid Spillage............................... 9
Diesel Exhaust Fluid .....................................11
Dispose of Waste Properly .......................... 10
F
Fluid Penetration ........................................... 9
Fault Logging................................................... 42 Inhalation ..................................................... 10
Features and Controls..................................... 31 Pressurized Air and Water............................. 9
Fire Prevention and Explosion Prevention...... 12 Static Electricity Hazard when Fueling with
Ether ............................................................ 13 Ultra-low Sulfur Diesel Fuel ......................... 9
Fire Extinguisher.......................................... 13 Grounding Stud - Inspect/Clean/Tighten....... 107
Lines, Tubes, and Hoses ............................. 14
Fluid Recommendations ........................... 62, 64 H
ELC Cooling System Maintenance.............. 66
Engine Oil .................................................... 62 Hoses and Clamps - Inspect/Replace........... 108
General Coolant Information ....................... 64 Fuel System............................................... 109
General Lubricant Information..................... 62 Replace the Hoses and the Clamps .......... 108
Fluid Recommendations (Diesel Exhaust
Fluid (DEF)) ................................................... 61 I
General Information..................................... 61
Important Safety Information............................. 2
Fluid Recommendations (General Fuel
Information) ................................................... 69
Contamination Control Recommendations for L
Fuels .......................................................... 76 Lifting and Storage .......................................... 25
Diesel Fuel Characteristics.......................... 72
Diesel Fuel Requirements ........................... 69
M0068760-05 117
Index Section

M Engine Specifications .................................. 21

Product Identification Information ................... 23
Maintenance Interval Schedule....................... 81
Product Information Section............................ 17
Daily ............................................................. 81
Product Lifting ................................................. 25
Every 10 000 Service Hours ........................ 82
Clean Emission Module (CEM) Lifting......... 27
Every 12 000 Service Hours or 6 Years....... 82
Engine Lifting ............................................... 26
Every 2000 Service Hours........................... 81
Pump Electronic Tank Unit (PETU) ............. 27
Every 250 Service Hours ............................. 81
Radiator Only............................................... 27
Every 2500 Service Hours........................... 81
Product Storage (Engine and
Every 3000 Service Hours or 3 Years ......... 81
Aftertreatment) .............................................. 27
Every 4000 Service Hours........................... 81
Condition for Storage................................... 27
Every 500 Service Hours ............................. 81
Every 500 Service Hours or 1 Year ............. 81
Every 500 Service Hours or 3 Months......... 81 R
Every 5000 Service Hours........................... 81 Radiator - Clean ............................................ 109
Every 6000 Service Hours or 3 Years ......... 82 Radiator Restrictions....................................... 58
Every 760 000 L (200 000 US gal) of Fuel or Reference Information Section ......................112
10 000 Service Hours ................................ 82 Reference Material (Extended Service
Initial 500 Service Hours.............................. 81 Contract).......................................................112
When Required............................................ 81 Reference Materials .......................................112
Maintenance Log............................................113 Refill Capacities............................................... 61
Maintenance Recommendations .................... 78 Refill Capacities and Recommendations ........ 77
Maintenance Records ....................................112 Recommendation ........................................ 77
Maintenance Section....................................... 61 Refill Capacities ........................................... 77
Manual Stop Procedure .................................. 56
Model View Illustrations .................................. 17
S
Aftertreatment System................................. 19
Clean Emission Module............................... 19 Safety Messages............................................... 6
Engine Views ............................................... 17 Sulfuric Acid Burn (2)..................................... 6
NOx Sensors and DEF Heated line............. 20 Universal Warning (1) .................................... 6
Pump Electronic Tank Unit (PETU) ............. 20 Safety Section ................................................... 6
Model Views .................................................... 17 Selective Catalytic Reduction Warning
Monitoring System........................................... 31 System........................................................... 36
Monitoring System Indicators ...................... 31 Definitions .................................................... 37
Mounting and Dismounting ............................. 14 Inducement Strategy for DEF Level
(European Union) ...................................... 37
O Inducement Strategy for DEF Level
(Worldwide)................................................ 39
Operation Section............................................ 25 Inducement Strategy for Escalating Time
Overhaul Considerations............................... 109 Inducement Faults (European Union) ....... 38
Inducement Strategy for Escalating Time
P Inducement Faults (Worldwide)................. 40
Self-Diagnostics .............................................. 42
Plate Locations and Film Locations ................ 23
Sensors and Electrical Components............... 31
Pump Electronic Tank Unit (PETU) and Pump
Aftertreatment System................................. 34
Electronic Unit (PEU)................................. 24
Engine.......................................................... 32
Product Description ......................................... 20
Pump Electronic Tank Unit (PETU) ............. 35
Aftermarket Products and Perkins
Severe Service Application ............................. 79
Engines ...................................................... 21
Environmental Factors................................. 80
Electronic Engine Features ......................... 21
Incorrect Maintenance Procedures ............. 80
Engine Diagnostics...................................... 21
Incorrect Operating Procedures .................. 80
Engine Service Life...................................... 21
Starting Motor - Inspect ................................. 109
118 M0068760-05
Index Section

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

Problems with the Wiring Harness .............. 48
Starting Problems ........................................ 47
Starting the Engine ...................................... 47
Starting with Jump Start Cables (Do Not
Use This Procedure in Hazardous
Locations that have Explosive
Atmospheres) ................................................ 48
Stopping the Engine ........................................ 55
Delayed Engine Shutdown (If Enabled) ...... 55
System Pressure Release............................... 78
Coolant System ........................................... 78
Engine Oil .................................................... 78
Fuel System................................................. 78

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

W
Walk-Around Inspection ................................ 109
Inspect the Engine for Leaks and for Loose
Connections ............................................. 109
Warranty Information...................................... 111
Warranty Section ............................................ 111
Welding on Engines with Electronic
Controls ......................................................... 78
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
M0068760
©2019 Perkins Engines Company Limited
All Rights Reserved

120 August 2019