SEBU7833-03 September 2008 Operation and Maintenance Manual 1103 and 1104 Industrial Engines DC (Engine) DD (Engine) DJ (Engine) DK (Engine) RE (Engine) RG (Engine) RJ (Engine) RR (Engine) RS (Engine) RT (Engine) DF (Engine) DG (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 properly.
SEBU7833-03 Table of Contents Foreword ................................................................. 4 Safety Section Safety Messages .................................................... 5 General Hazard Information ................................... 6 Burn Prevention ...................................................... 7 Fire Prevention and Explosion Prevention .............. 8 Crushing Prevention and Cutting Prevention ........ 10 Mounting and Dismounting ...................................
Foreword Foreword Literature Information This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information. English is the primary language for all Perkins publications. The English used facilitates translation and consistency.
SEBU7833-03 5 Safety Section Safety Messages Safety Section i03299360 Safety Messages There may be several specific warning signs on an engine. The exact location of the hazards and the description of the hazards are reviewed in this section. Please become familiar with all warning signs. Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the pictures are not visible.
Safety Section General Hazard Information SEBU7833-03 i02328435 General Hazard Information Illustration 3 g01682820 The ether warning label (2) is located on the cover of the inlet manifold. Refer to illustration 4. Illustration 5 g00104545 Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment.
SEBU7833-03 7 Safety Section Burn Prevention Report all necessary repairs. Do not allow unauthorized personnel on the equipment. Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs. Perform maintenance on the engine with the equipment in the servicing position. Refer to the OEM information for the procedure for placing the equipment in the servicing position. Pressure Air and Water Pressurized air and/or water can cause debris and/or hot water to be blown out.
Safety Section Fire Prevention and Explosion Prevention SEBU7833-03 Coolant All fuels, most lubricants, and some coolant mixtures are flammable. When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or 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.
SEBU7833-03 9 Safety Section Fire Prevention and Explosion Prevention Arcing or sparking could cause a fire. Secure connections, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking. Inspect all lines and hoses for wear or for deterioration. The hoses must be correctly routed. The lines and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires.
Safety Section Crushing Prevention and Cutting Prevention SEBU7833-03 Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque.
SEBU7833-03 11 Safety Section Engine Starting Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage. See the Service Manual for repairs and for adjustments. i02207232 Engine Starting Note: The engine is equipped with an automatic device for cold starting for normal conditions of operation.
Safety Section Electrical System Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specific starting instructions. Grounding Practices Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability.
SEBU7833-03 13 Product Information Section Model Views Product Information Section Model Views i01928892 Model View Illustrations 1104 Engine Model Views g01012280 Illustration 11 (1) Valve mechanism cover (2) Crankcase breather (3) Fuel filter (4) Fuel injection pump (5) Engine oil filter (6) Crankshaft pulley (7) Water pump (8) Fan pulley (9) Water temperature regulator housing
Product Information Section Model Views SEBU7833-03 g01012281 Illustration 12 (1) Oil filler cap (2) Exhaust manifold (3) Alternator (4) Turbocharger (5) Starter motor (6) Flywheel housing (7) Flywheel (8) Air intake
SEBU7833-03 15 Product Information Section Model Views 1103 Engine Model Views g01011348 Illustration 13 (1) Alternator (2) Fan pulley (3) Turbocharger oil supply (4) Turbocharger oil drain (5) Turbocharger (6) exhaust manifold
Product Information Section Model Views SEBU7833-03 g01011349 Illustration 14 (1) (2) (3) (4) Fuel transfer pump Oil filler cap Fuel filter Starter motor (5) (6) (7) (8) Dipstick Oil filter Oil pan Crankshaft pulley i02196981 Engine Description Perkins Engines are designed for the following applications: machine, genset, and industrial mobile equipment.
SEBU7833-03 17 Product Information Section Model Views Table 2 1103 Industrial Engine Specifications Number of Cylinders Bore 105 mm (4.134 inch) Stroke 127 mm (5.0 inch) Aspiration Turbocharged Naturally aspirated Compression Ratio Displacement g00984281 Illustration 15 (A) Inlet valves (B) Exhaust valves Table 1 1104 Industrial Engine Specifications Number of Cylinders Bore Stroke Aspiration 127 mm (5.0 inch) Turbocharged aftercooled Turbocharged Naturally aspirated Compression Ratio NA 19.
Product Information Section Model Views SEBU7833-03 Engine Service Life Table 4 1103 Genset Specifications Number of Cylinders Bore 3 In-Line 105 mm (4.134 inch) Stroke 127 mm (5.0 inch) Aspiration Turbocharged Naturally aspirated Compression Ratio Displacement NA 19.25:1 T 17.25:1 3.3 L (201 in3) 1 2 3 Firing Order Rotation (flywheel end) Counterclockwise Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Valve Lash Setting (Exhaust) 0.45 mm (0.
SEBU7833-03 19 Product Information Section Product Identification Information Product Identification Information i01940474 Serial Number Plate i02280116 Engine Identification Perkins engines are identified by a serial number. This number is shown on a serial number plate that is mounted on the left hand side of the engine block. An example of an engine number is RE12345U090001H.
Product Information Section Product Identification Information SEBU7833-03 Engine Full Load rpm _____________________________________ Primary Fuel Filter _________________________________________ Water Separator Element ________________________________ Secondary Fuel Filter Element __________________________ Lubrication Oil Filter Element ___________________________ Auxiliary Oil Filter Element _______________________________ Total Lubrication System Capacity _____________________ Total Cooling System
SEBU7833-03 Illustration 17 21 Product Information Section Product Identification Information g01173630 This typical example of a label is installed on engines that have electronic fuel injection systems and installed on engines that have electronic fuel injection pumps. Illustration 18 This typical example of a label is installed on engines that have mechanical fuel injection pumps.
Product Information Section Product Identification Information SEBU7833-03 Label for engines that comply with MSHA emissions Illustration 19 g01381316 Typical example The label that is shown in illustration 19 is for engines that operate in underground coal mines in North America. The label is installed on engines that comply with the Mine Safety and Health Administration (MSHA) emissions. Approved diesel engines shall be identified by an approved mark that is legible and permanent.
SEBU7833-03 Illustration 21 This typical example of a label is installed on engines that are stationary engines.
Operation Section Lifting and Storage SEBU7833-03 Operation Section Some removals require lifting the fixtures in order to obtain correct balance and safety. To remove the engine ONLY, use the lifting eyes that are on the engine. Lifting and Storage i02164186 Engine Lifting Lifting eyes are designed and installed for specific engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete.
SEBU7833-03 25 Operation Section Lifting and Storage • Renew the canister(s) of the lubricating oil filter. • Fill the oil pan to the Full Mark on the dipstick with new, clean lubricating oil. Add 1762811 POWERPART Lay-Up 2 to the oil in order to protect the engine against corrosion. If 1762811 POWERPART Lay-Up 2 is not available, use a preservative of the correct specification instead of the lubricating oil.
Operation Section Lifting and Storage General Items • If the lubricating oil filler is installed on the rocker cover, remove the filler cap. If the lubricating oil filler cap is not installed on the rocker cover, remove the rocker cover. Spray 1762811 POWERPART Lay-Up 2 around the rocker shaft assembly. Replace the filler cap or the rocker cover. • Seal the vent of the fuel tank or the fuel filler cap with waterproof tape. • Remove the alternator drive belts and put the drive belts into storage.
SEBU7833-03 27 Operation Section Gauges and Indicators Gauges and Indicators 1. Reduce the load and the engine rpm. 2. Inspect the cooling system for leaks. i02164190 Gauges and Indicators Your engine may not have the same gauges or all of the gauges that are described. For more information about the gauge package, see the OEM information. Gauges provide indications of engine performance. Ensure that the gauges are in good working order.
Operation Section Engine Starting SEBU7833-03 Engine Starting • Do not start the engine or move any of the controls i02194223 Before Starting Engine if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls. • Ensure that the areas around the rotating parts are clear. Before the engine is started, perform the required daily maintenance and any other periodic maintenance that is due.
SEBU7833-03 29 Operation Section Engine Starting i02198348 Starting the Engine When Group 2 diesel fuel is used, the following items provide a means of minimizing starting problems and fuel problems in cold weather: engine oil pan heaters, jacket water heaters, fuel heaters, and fuel line insulation. Use the procedure that follows for cold weather starting. Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.
Operation Section Engine Starting SEBU7833-03 i02177935 Starting with Jump Start Cables 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. 4. Start the engine.
SEBU7833-03 31 Operation Section Engine Operation Engine Operation i02330149 Fuel Conservation Practices i02176671 Engine Operation Correct operation and maintenance are key factors in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenance Manual are followed, costs can be minimized and engine service life can be maximized. The engine can be operated at the rated rpm after the engine reaches operating temperature.
Operation Section Engine Stopping SEBU7833-03 Engine Stopping i01903608 After Stopping Engine i01929389 Stopping the Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. NOTICE Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components.
SEBU7833-03 33 Operation Section Cold Weather Operation Cold Weather Operation i02717265 Cold Weather Operation • Install the correct specification of engine lubricant before the beginning of cold weather. • Check all rubber parts (hoses, fan drive belts, etc) weekly. • Check all electrical wiring and connections for any fraying or damaged insulation. Perkins Diesel Engines can operate effectively in cold weather.
Operation Section Cold Weather Operation SEBU7833-03 In cold weather, check the coolant often for the correct glycol concentration in order to ensure adequate freeze protection. • Free operation of the valves is prevented. Engine Block Heaters • Pushrods may become bent. Engine block heaters (if equipped) heat the engine jacket water that surrounds the combustion chambers. This provides the following functions: • Other damage to valve train components can • Startability is improved.
SEBU7833-03 35 Operation Section Cold Weather Operation A cab heater is beneficial in very cold weather. The feed from the engine and the return lines from the cab should be insulated in order to reduce heat loss to the outside air.
Operation Section Cold Weather Operation SEBU7833-03 i01903588 Fuel Related Components in Cold Weather Fuel Tanks Condensation can form in partially filled fuel tanks. Top off the fuel tanks after you operate the engine. Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks. Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe.
SEBU7833-03 37 Maintenance Section Refill Capacities Maintenance Section Cooling System Refill Capacities i02198350 Refill Capacities 1104 Engine Lubrication System The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter.
Maintenance Section Refill Capacities SEBU7833-03 1103 Engine API Oils Table 9 The Engine Oil Licensing and Certification System by the American Petroleum Institute (API) is recognized by Perkins. For detailed information about this system, see the latest edition of the “API publication No. 1509”. Engine oils that bear the API symbol are authorized by API. 1103 Naturally Aspirated Engine without an oil cooler Compartment or System Engine Only Liters Quarts 4.
SEBU7833-03 Engine Oil Commercial Oils The performance of commercial diesel engine oils is based on American Petroleum Institute (API) classifications. These API classifications are developed in order to provide commercial lubricants for a broad range of diesel engines that operate at various conditions.
Maintenance Section Refill Capacities SEBU7833-03 Table 12 NOTICE Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear. Total Base Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines The Total Base Number (TBN) for an oil depends on the fuel sulfur level. For direct injection engines that use distillate fuel, the minimum TBN of the new oil must be 10 times the fuel sulfur level.
SEBU7833-03 41 Maintenance Section Refill Capacities Some synthetic base oils have performance characteristics that enhance the service life of the oil. Perkins does not recommend the automatic extending of the oil change intervals for any type of oil. NOTICE Shortened engine service life could result if second choice oils are used.
Maintenance Section Refill Capacities SEBU7833-03 • The Wear Rate Analysis monitors the wear of the High sulfur content of the fuel is not normally found in Europe, North America or Australasia. This can cause engine wear. When only high sulfur fuels are available, it will be necessary that high alkaline lubricating oil is used in the engine or that the lubricating oil change interval is reduced.
SEBU7833-03 “ASTM D975 - 91 Class 1D” “JP7, Mil T38219” “NATO F63” NOTICE These fuels should have a wear scar value of 650 micrometers maximum *HFRR to ISO 12156 - 1.* Group 3 (aviation kerosene fuels): Specification These fuels need additives to achieve lubricity of 650 micrometers wear scar and the reliability of the fuel injection pump will be reduced. The fuel injection pump is not covered by a warranty, even when the additives are included.
Maintenance Section Refill Capacities SEBU7833-03 (Table 14, contd) Copper Strip Corrosion Distillation Flash Point API Gravity Pour Point Sulfur No. 3 maximum 10% at 282 °C (540 °F) maximum 90% at 360 °C (680 °F) maximum legal limit 30 minimum 45 maximum 6 °C (10 °F) minimum below ambient temperature 0.2% maximum (1) Kinematic Viscosity (2) 2.0 cSt minimum and 4.5 cSt maximum at 40 °C (104 °F) “D130” “D86” “D93” “D287” “D3605” or “D1552” “D445” Water 0.1% maximum “D1744” Sediment 0.
SEBU7833-03 Cooling System Specifications General Coolant Information NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first. 45 Maintenance Section Refill Capacities DO NOT use the following types of water in cooling systems: Hard water, softened water that has been conditioned with salt, and sea water. If distilled water or deionized water is not available, use water with the properties that are listed in Table 16.
Maintenance Section Refill Capacities SEBU7833-03 Glycol Glycol in the coolant helps to provide protection against the following conditions: Acceptable – A commercial heavy-duty coolant/antifreeze that meets “ASTM D4985” specifications NOTICE Do not use a commercial coolant/antifreeze that only meets the ASTM D3306 specification. This type of coolant/antifreeze is made for light automotive applications.
SEBU7833-03 47 Maintenance Section Refill Capacities • Heavy-duty diesel engines • Automotive applications The anti-corrosion package for ELC is different from the anti-corrosion package for other coolants. ELC is an ethylene glycol base coolant. However, ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite.
Maintenance Section Refill Capacities SEBU7833-03 ELC Cooling System Cleaning Note: If the cooling system is already using ELC, cleaning agents are not required to be used at the specified coolant change interval. Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage. Clean water is the only cleaning agent that is required when ELC is drained from the cooling system.
SEBU7833-03 49 Maintenance Section Refill Capacities Commercial Heavy-Duty Coolant/ Antifreeze and SCA NOTICE Commercial Heavy-Duty Coolant which contains Amine as part of the corrision protection system must not be used. NOTICE Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the correct operating temperature. Cooling system problems can develop without water temperature regulators.
Maintenance Section Refill Capacities Cleaning the System of Heavy-Duty Coolant/Antifreeze Perkins cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion. Perkins cooling system cleaners dissolve mineral scale, corrosion products, light oil contamination and sludge. • Clean the cooling system after used coolant is drained or before the cooling system is filled with new coolant.
SEBU7833-03 51 Maintenance Section Maintenance Interval Schedule i03302982 Maintenance Interval Schedule Every 2 Years Cooling System Coolant - Change ....................... 58 Every 3000 Service Hours Fuel Injector - Test/Change ................................... 68 When Required Battery - Replace .................................................. Battery or Battery Cable - Disconnect .................. Engine - Clean ......................................................
Maintenance Section Aftercooler Core - Clean/Test SEBU7833-03 i02322260 Aftercooler Core - Clean/Test Personal injury can result from air pressure. 1. Remove the core. Refer to the OEM information for the correct procedure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. 2. Turn the aftercooler core upside-down in order to remove debris.
SEBU7833-03 53 Maintenance Section Alternator - Inspect After cleaning, start the engine and accelerate the engine to high idle rpm. This will help in the removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary. For applications that require multiple drive belts, replace the belts in matched sets.
Maintenance Section Battery - Replace SEBU7833-03 2. Move the alternator in order to increase or decrease the belt tension. Tighten the alternator pivot bolt and the link bolt to 22 N·m (16 lb ft).(1). 5. Remove the used battery. 6. Install the new battery. Replacement Note: Before the cables are connected, ensure that the engine start switch is OFF. Refer to the Disassembly and Assembly Manual for the installation procedure and the removal procedure for the belt. 7.
SEBU7833-03 55 Maintenance Section Battery or Battery Cable - Disconnect i02323088 Battery or Battery Cable Disconnect The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury. 1. Turn the start switch to the OFF position.
Maintenance Section Cooling System Coolant (Commercial Heavy-Duty) - Change 1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. SEBU7833-03 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the drain cock or remove the drain plug on the engine.
SEBU7833-03 57 Maintenance Section Cooling System Coolant (ELC) - Change i02203595 Cooling System Coolant (ELC) - Change 1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
Maintenance Section Cooling System Coolant - Change 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Open the drain cock or remove the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the water to drain. Flush the cooling system with clean water. SEBU7833-03 i01929799 Cooling System Coolant Change Fill 1.
SEBU7833-03 59 Maintenance Section Cooling System Coolant Extender (ELC) - Add i02335364 Cooling System Coolant Extender (ELC) - Add The Perkins Extended Life Coolant (ELC) does not need the frequent addition of Supplemental Coolant Additives (SCA) that are associated with conventional coolants. The Extender only needs to be added once. Check the cooling system only when the engine is stopped and cool. 1. Loosen the cooling system filler cap slowly in order to relieve pressure.
Maintenance Section Driven Equipment - Check SEBU7833-03 • Lubrication • Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM. i01930350 Engine - Clean Illustration 32 g00285520 Personal injury or death can result from high voltage. Cooling system filler cap Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool.
SEBU7833-03 61 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace i01915869 Engine Air Cleaner Element (Dual Element) - Clean/Replace NOTICE 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 with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components.
Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace SEBU7833-03 Cleaning the Primary Air Cleaner Elements NOTICE Observe the following guidelines if you attempt to clean the filter element: Do not tap or strike the filter element in order to remove dust. Do not wash the filter element. Use low pressure compressed air in order to remove the dust from the filter element. Air pressure must not exceed 207 kPa (30 psi).
SEBU7833-03 63 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace Inspect the clean, dry primary air cleaner element. Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air cleaner element. Rotate the primary air cleaner element. Inspect the primary air cleaner element for tears and/or holes. Inspect the primary air cleaner element for light that may show through the filter material.
Maintenance Section Engine Ground - Inspect/Clean SEBU7833-03 i01941505 Engine Ground - Inspect/Clean Inspect the wiring harness for good connections. Perkins use the starter motor in order to ground the engine. Check the connection on the starter motor at every oil change. Ground wires and straps should be combined at engine grounds. All grounds should be tight and free of corrosion. • Clean the grounding stud on the starter motor and the terminals with a clean cloth.
SEBU7833-03 Perkins recommends using a sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when a sampling valve is used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation. Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Maintenance Section Engine Oil and Filter - Change SEBU7833-03 After the oil has drained, the oil drain plugs should be cleaned and installed. If necessary, renew the O ring seal on the drain plug. Some types of oil pans have oil drain plugs that are on both sides of the oil pan, because of the shape of the pan. This type of oil pan requires the engine oil to be drained from both plugs. Replace the Spin-on Oil Filter NOTICE Perkins oil filters are manufactured to Perkins specifications.
SEBU7833-03 67 Maintenance Section Engine Valve Lash - Inspect/Adjust 2. Locate a suitable wrench into the square hole (2) in order to remove the filter bowl (3). 3. Remove the filter bowl (3) and remove the element from the filter bowl. Clean the filter bowl. NOTICE To prevent crankshaft bearing damage, crank the engine with the fuel OFF. This will fill the oil filters before starting the engine. Do not crank the engine for more than 30 seconds. 2.
Maintenance Section Fuel Injector - Test/Change SEBU7833-03 Ensure that the engine can not be started while this maintenance is being performed. To help prevent 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. Ensure that the engine is stopped before measuring the valve lash.
SEBU7833-03 69 Maintenance Section Fuel System - Prime Removal and Installation of the Fuel Injectors Use the following procedure in order to remove air from the fuel system: 1. Ensure that all low pressure fuel connections and high pressure fuel lines are installed correctly. Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury. 2. Turn the ignition key to the RUN position.
Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace i02206563 Fuel System Primary Filter (Water Separator) Element Replace SEBU7833-03 2. Place a suitable container under the water separator. Clean the outside of the water separator. 3. Open the drain (5). Allow the fluid to drain into the container. 4. Tighten the drain (5) by hand pressure only. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
SEBU7833-03 71 Maintenance Section Fuel System Secondary Filter - Replace 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 disconnected fuel system component. Element filter Turn the valves for the fuel lines (if equipped) to the OFF position before performing this maintenance. Place a tray under the fuel filter in order to catch any fuel that might spill. Clean up any spilled fuel immediately.
Maintenance Section Fuel System Secondary Filter - Replace Illustration 48 SEBU7833-03 g01010595 (3) O ring seal (4) Element (5) Filter head 3. Remove the filter bowl (2) from the filter head (5). Press on the element (4). Rotate the element counterclockwise in order to release the element for the filter bowl and remove the element from the bowl. Discard the used element. 4. Remove the O ring (3) from the filter bowl and clean the filter bowl.
SEBU7833-03 73 Maintenance Section Fuel Tank Water and Sediment - Drain Water can be introduced into the fuel tank when the fuel tank is being filled. Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.
Maintenance Section Hoses and Clamps - Inspect/Replace SEBU7833-03 i02813964 Hoses and Clamps Inspect/Replace • Anticipated expansion and contraction of the hose • Anticipated expansion and contraction of the fittings Replace the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following conditions: Refer to the OEM information for further information on removing and replacing fuel hoses (if equipped).
SEBU7833-03 75 Maintenance Section Radiator - Clean i02335774 Radiator - Clean The radiator is not usually supplied by Perkins. The following text describes a typical cleaning procedure for the radiator. Refer to the OEM information for further information on cleaning the radiator. Inspect the fins for damage. Bent fins may be opened with a “comb”. Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.
Maintenance Section Starting Motor - Inspect SEBU7833-03 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.
SEBU7833-03 77 Maintenance Section Walk-Around Inspection For options regarding the removal, installation, and replacement, consult your Perkins dealer or your Perkins distributor. Refer to the Disassembly and Assembly Manual, “Turbocharger - Remove and Turbocharger - Install” for further information. Inspecting NOTICE The compressor housing for the turbocharger must not be removed from the turbocharger for cleaning. The actuator linkage is connected to the compressor housing.
Maintenance Section Water Pump - Inspect SEBU7833-03 Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt could cause the belt to break. • Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system.
SEBU7833-03 79 Warranty Section Warranty Information Warranty Section Warranty Information i01903596 Emissions Warranty Information This engine may be certified to comply with exhaust emission standards and gaseous emission standards that are prescribed by the law at the time of manufacture, and this engine may be covered by an Emissions Warranty.
Index Section SEBU7833-03 Index E A After Starting Engine ............................................. After Stopping Engine............................................ Aftercooler Core - Clean/Test ................................ Aftercooler Core - Inspect...................................... Alternator - Inspect ................................................ Alternator and Fan Belts - Inspect/Adjust/ Replace................................................................ Adjustment ............
SEBU7833-03 Fluid Recommendations........................................ 38 Cooling System Specifications........................... 45 ELC Cooling System Maintenance .................... 47 Engine Oil .......................................................... 39 Fuel Specifications............................................. 42 General Lubricant Information ........................... 38 Foreword ................................................................. 4 California Proposition 65 Warning ......
Index Section SEBU7833-03 W Walk-Around Inspection ........................................ Inspect the Engine for Leaks and for Loose Connections ..................................................... Warranty Information ............................................. Warranty Section ................................................... Water Pump - Inspect............................................
Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual.
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