SEBU8726-03 (en-us) June 2016 Operation and Maintenance Manual 854E-E34TA 854F-E34T and 854FE34TA Industrial Engines JR (Engine) JS (Engine) JT (Engine) JV (Engine) This document has been printed from SPI2.
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.
SEBU8726-03 Table of Contents Table of Contents Foreword ........................................................... 4 Safety Section Safety Messages............................................... 5 General Hazard Information.............................. 6 Burn Prevention................................................. 9 Maintenance Section Refill Capacities............................................... 67 Maintenance Recommendations .................... 82 Maintenance Interval Schedule...........
SEBU8726-03 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.
SEBU8726-03 Safety Section Safety Messages Safety Section i04112132 Safety Messages There may be several specific warning signs on your engine. The exact location and a description of the warning signs 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 illustrations are not visible.
SEBU8726-03 Safety Section General Hazard Information Illustration 2 g02582556 Typical example i06702758 General Hazard Information • 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.
SEBU8726-03 Safety Section General Hazard Information • The protective locks or the controls are in the applied position. • Engage the secondary brakes or parking brakes. • Block the vehicle or restrain the vehicle before maintenance or repairs are performed. Use caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts or nuts that are at opposite ends of the cover plate or the device.
SEBU8726-03 Safety Section General Hazard Information Pressurized Air and Water Pressurized air and/or water can cause debris and/or hot water to be blown out and could result in personal injury. When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi).
SEBU8726-03 Safety Section Burn Prevention • Use exhaust ventilation on permanent machining jobs. Avoid static electricity risk when fueling. Ultralow sulfur diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur contents. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.
SEBU8726-03 Safety Section Burn Prevention Allow the engine system to cool before any maintenance is performed. Relieve all pressure in the following systems, hydraulic system, lubrication system, fuel system, and the cooling system before related items are disconnected. Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard.
SEBU8726-03 Safety Section Fire Prevention and Explosion Prevention i04303237 Fire Prevention and Explosion Prevention Do not weld on lines or tanks that contain flammable 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. All electrical wires must be correctly routed and securely attached. Check all electrical wires daily.
SEBU8726-03 Safety Section Fire Prevention and Explosion Prevention Incorrect jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions. Do not charge a frozen battery. Charging 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.
SEBU8726-03 Safety Section Crushing Prevention and Cutting Prevention Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this check will help to prevent vibration, rubbing against other parts, and excessive heat. i04112191 High Pressure Fuel Lines Regeneration The exhaust gas temperature during regeneration will be elevated. Follow proper fire prevention instructions and use the disable switch function when appropriate.
SEBU8726-03 Safety Section High Pressure Fuel Lines Illustration 11 (1) High-pressure line (2) High-pressure line g02315653 (3) High-pressure line (4) High-pressure line The high-pressure fuel lines are the fuel lines that are between the high-pressure fuel pump and the highpressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel systems.
SEBU8726-03 Safety Section Before Starting Engine i05874054 Before Starting Engine NOTICE For initial start-up of a new or rebuilt engine, and for start-up of an engine that has been serviced, make provision to shut the engine off should an overspeed occur. This may be accomplished by shutting off the air and/or fuel supply to the engine. Engine exhaust contains products of combustion which may be harmful to your health.
SEBU8726-03 Safety Section Electrical System i04112409 Electrical System Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite. To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” cable should be connected last from the external power source to the negative “−” terminal of the starting motor.
SEBU8726-03 Safety Section Engine Electronics The power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery. i04346349 • Engine Aftertreatment System 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.
SEBU8726-03 Product Information Section General Information Product Information Section General Information i06703805 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.
SEBU8726-03 Product Information Section Model View Illustrations Illustration 15 g03367502 Typical example (13) Secondary fuel filter (14) Oil filter (15) Oil level gauge (Dipstick) (16) High-pressure fuel pump (17) Valve mechanism cover This document has been printed from SPI2.
SEBU8726-03 Product Information Section Model View Illustrations Illustration 16 (18) Rear lifting eyes (19) Front lifting eye (20) Crankcase breather g03367547 (21) Oil filler cap (22) Belt (23) Coolant pump (24) Coolant outlet connection (25) Air inlet connection The oil filler cap (21) can also be located on the valve mechanism cover. This document has been printed from SPI2.
SEBU8726-03 Product Information Section Model View Illustrations Off Engine Parts Illustration 17 (26) Fuel priming pump (27) Primary fuel filter g06082900 (28) Differential pressure sensor (29) Electronic control module (30) Relay for glow plugs (31) Breather heater This document has been printed from SPI2.
SEBU8726-03 Product Information Section Model View Illustrations Engine View with Wall Flow Diesel Particulate Filter Illustration 18 g03367096 Typical example The wall flow Diesel Particulate Filter (DPF) will require a service, refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for the service period. This document has been printed from SPI2.
SEBU8726-03 23 Product Information Section Model View Illustrations Top Mounted Aftertreatment Illustration 19 g06082892 Typical example This document has been printed from SPI2.
SEBU8726-03 Product Information Section Product Description The wall flow Diesel Particulate Filter (DPF) will require a service, refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for the service period. Engine View with Through Flow Diesel Particulate Filter Illustration 20 g03367094 Typical example The through-flow type of DPF will not require a service interval.
SEBU8726-03 Product Information Section Product Description • JV 854F-E34TA is a turbocharged, charge cooled engine with a wall flow DPF The JV model 854F-E34TA is a constant power output engine, rated at 2200 RPM. The through-flow aftertreatment system DPF will not require a service period. The wall flow aftertreatment system DPF will require a service period. For more information refer to this “Operation and Maintenance Manual”Maintenance Interval Schedule.
SEBU8726-03 Product Information Section Product Description The ECM provides an electronic governor that controls the injector output to maintain the desired engine rpm.
SEBU8726-03 Product Information Section Product Identification Information Product Identification Information Serial Number location i04725109 Plate Locations and Film Locations (Engine) S Perkins engines are identified by an engine serial number. An example of an engine number is JR*****L000001V.
SEBU8726-03 Product Information Section Engine Illustration 23 g02826736 Typical example On a stressed cylinder block the serial number is located in position (3). This document has been printed from SPI2.
SEBU8726-03 Product Information Section Plate Locations and Film Locations The engine serial number is stamped on the emissions plate. i05328112 Plate Locations and Film Locations (Aftertreatment) Wall Flow Diesel Particulate Filter (DPF) Illustration 24 g02475495 Typical example The serial number for identifying the aftertreatment will be in two locations. On the DPF in position (1) and in position (2). On the end cover of the inlet to the DPF. This document has been printed from SPI2.
SEBU8726-03 Product Information Section Plate Locations and Film Locations Illustration 25 (1) Serial numbers on main body g02723697 (2) Serial numbers on inlet end cover Ensure that all numbers on the aftertreatment are recorded. Your Perkins distributor or your dealer will require all the numbers in order to identify the components for your aftertreatment.
SEBU8726-03 Product Information Section Reference Information Illustration 26 g02646428 Typical example i05324886 Reference Information Engine Aftertreatment System Part Number Serial Number Information for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Make a copy of this list for a record. Keep the information for future reference.
SEBU8726-03 Operation Section Lifting and Storage Operation Section Some removals require lifting the fixtures to obtain correct balance and safety. Lifting and Storage To remove the engine, use the lifting eyes that are on the engine. Radiators that are approved by Perkins can be lifted with the engine. i06704010 Product Lifting Lifting eyes are designed and installed for specific engine arrangements.
SEBU8726-03 33 Operation Section Engine and Aftertreatment b. Fill the fuel system with an ultra low sulfur fuel. For more information on acceptable fuels refer to this Operation and Maintenance Manual, “Fluid recommendations”. Operate the engine for 15 minutes in order to remove all biodiesel from the system. 2. Drain any water from the primary filter water separator. Ensure that the fuel tank is full. 3. The engine oil will not need to be drained in order to store the engine.
SEBU8726-03 Operation Section Features and Controls Features and Controls i05324913 Alarms and Shutoffs The alarm is a warning to the operator that an abnormal operating condition has occurred. The shutoffs are set in order to protect the engine from damage. A shutoff can be triggered by pressure, temperature, engine speed, and electronic fault. The operator should become familiar with the warning lamps and shutdown lamps on the installed control panel before operating the application.
SEBU8726-03 Operation Section Monitoring System Indicator Lamps NOTICE The Engine Monitoring System is not a guarantee against catastrophic failures. Programmed delays and derate schedules are designed to minimize false alarms and provide time for the operator to stop the engine.
SEBU8726-03 Operation Section Monitoring System The engine will be derated if the engine exceeds preset operational limits. The engine derate is achieved by restricting the amount of fuel that is available for each injection. The amount of this reduction of fuel is dependent on the severity of the fault that has caused the engine derate, typically up to a limit of 50%. This reduction in fuel results in a predetermined reduction in engine power.
SEBU8726-03 Operation Section Overspeed Table 2 Warning Indicator Shutdown Indicator On On Lamp State Description of the Indication Engine Status Indicator Check When the keyswitch is moved to The keyswitch is in the ON the ON position, the lamps will illu- position but the engine has minate for 2 seconds and the lamps not yet been cranked. will then go off. During indicator check, the aftertreatment indicators will also be checked.
SEBU8726-03 Operation Section Sensors and Electrical Components i05325438 Sensors and Electrical Components Full Engine Views Illustration 28 g03373765 Typical example (1) 10 Pin and 62 pin connector (2) Fuel temperature sensor (3) Oil pressure switch (4) Primary speed/timing sensor (crankshaft position sensor) (5) Water in fuel switch (6) Fuel metering valve This document has been printed from SPI2.
SEBU8726-03 Operation Section Sensors and Electrical Components Illustration 29 g02477200 Typical example (7) Fuel manifold (rail) pressure sensor (8) Electronic control module (9) Secondary speed/timing sensor (camshaft position sensor) (10) Alternator (11) Coolant temperature sensor (12) Intake throttle valve This document has been printed from SPI2.
SEBU8726-03 Operation Section Sensors and Electrical Components Illustration 30 g02529496 Typical example (13) Inlet manifold pressure and temperature sensor. (14) Exhaust temperature sensor connection (15) Exhaust pressure sensor (16) Waste gate regulator (17) Starting motor (18) Oxygen sensor (19) Control valve for the NOx reduction system Note: Item (13), lower powered engines have separate inlet manifold pressure sensors and inlet manifold temperature sensors.
SEBU8726-03 Operation Section Sensors and Electrical Components Engine View Low Power with Separate Inlet Pressure and Inlet Temperature Illustration 31 g03373789 Typical example (13 A) Inlet pressure sensor (13 B) Inlet temperature sensor This document has been printed from SPI2.
SEBU8726-03 Operation Section Sensors and Electrical Components Location Views Illustration 32 g03373767 Typical example (1) 10 Pin and 62 pin connector (2) Fuel temperature sensor (3) Oil pressure switch (4) Primary speed/timing sensor (crankshaft position sensor) (5) Water in fuel switch (6) Fuel metering valve This document has been printed from SPI2.
SEBU8726-03 Operation Section Sensors and Electrical Components Illustration 33 g02529820 Typical example (7) Fuel manifold (rail) pressure sensor (8) Electronic control module (9) Secondary speed/timing sensor (camshaft position sensor) (10) Alternator (11) Coolant temperature sensor (12) Intake throttle valve Note: The location of item (8) the engine electronic control module will depend on the application. This document has been printed from SPI2.
SEBU8726-03 Operation Section Sensors and Electrical Components Illustration 34 g02529821 Typical example (13) Inlet manifold pressure and temperature sensor. (14) Exhaust temperature sensor connection (A) Exhaust temperature sensor (15) Exhaust pressure sensor (16) Waste gate regulator This document has been printed from SPI2.
SEBU8726-03 Operation Section Sensors and Electrical Components Illustration 35 g02530397 Typical example (17) Starting motor (18) Position for oxygen sensor (19) NOx reduction control valve Note: Some engines can have the air intake temperature sensor and the glow plug control unit supplied loose. This document has been printed from SPI2.
SEBU8726-03 Operation Section Sensors and Electrical Components Separate Inlet Pressure and Inlet Temperature Views Illustration 36 g03373791 Typical example (13 A) Intake manifold pressure sensor (13 B) Intake manifold temperature sensor This document has been printed from SPI2.
SEBU8726-03 Operation Section Sensors and Electrical Components Engine Option or Parts that are Supplied Loose Illustration 37 g02821639 Typical example (20) Glow plug control unit (21) Inlet air temperature sensor (22) Breather heater Some engines can have a breather heater (22) for the crankcase breather installed. i05325624 Sensors and Electrical Components (Aftertreatment) There are two types of aftertreatment that can be installed.
SEBU8726-03 Operation Section Aftertreatment Wall Flow Aftertreatment Illustration 38 g03373851 Typical example (1) Diesel oxidation catalyst temperature sensor (2) Diesel particulate filter (DPF) temperature sensor (3) Inlet connection for the differential pressure sensor (4) Outlet connection for the differential pressure sensor (5) Oxygen sensor Through Flow Aftertreatment Illustration 39 g03373872 Typical example (1) Diesel oxidation catalyst (DOC) temperature sensor (2) Temperature sens
SEBU8726-03 Operation Section Aftertreatment Differential Pressure sensor Illustration 40 g02477086 Typical example (1) Differential pressure sensor The location of the differential pressure sensor will depend on the application. The differential pressure is installed on the wall flow DPF. The through-flow DPF does not always require the sensor to be installed. This document has been printed from SPI2.
SEBU8726-03 Operation Section Engine Diagnostics Engine Diagnostics i04348749 i02651093 Self-Diagnostics Perkins electronic engines have the capability to perform a self-diagnostics test. When the system detects an active problem, a diagnostic lamp is activated. Diagnostic codes will be stored in permanent memory in the Electronic Control Module (ECM). The diagnostic codes can be retrieved by using the electronic service tool.
SEBU8726-03 Operation Section Configuration Parameters In most cases, it is not necessary to stop the engine because of an intermittent code. However, the operator should retrieve the logged fault codes and the operator should reference the appropriate information in order to identify the nature of the event. The operator should log any observation that could have caused the lamp to light.
SEBU8726-03 Operation Section Configuration Parameters (Table 3, contd) Throttle Position 1 Engine Speed Throttle Position 2 Engine Speed Throttle Position 3 Engine Speed Throttle Position 4 Engine Speed Engine Idle Shutdown Enable Status Engine Idle Shutdown Delay Status Throttle Lock Feature Installation Status Multi State Input Switch Enable Status Multi State Input Switch Control Purpose Multi Position Throttle Switch Initialization Enable Status Throttle Lock Engine Set Speed #1 Throttle Lock Inc
SEBU8726-03 53 Operation Section Configuration Parameters (Table 3, contd) Throttle #2 Initial Upper Position Throttle #2 Idle Validation Switch Enable Status Throttle #2 Idle Validation Minimum Off Threshold Throttle #2 Idle Validation Maximum On Threshold Throttle #2 Lower Diagnostic Limit Throttle #2 Upper Diagnostic Limit Engine Operation Mode #1 High Idle Speed Engine Operation Mode #1 High Idle Droop Percentage Engine Operation Mode #1 Throttle #1 Droop Percentage Engine Operation Mode #1 Throttle #
SEBU8726-03 Operation Section Engine Starting Engine Starting i05365825 Cold Weather Starting i03648917 Before Starting Engine Perform the required daily maintenance and other periodic maintenance before the engine is started. Inspect the engine compartment. This inspection can help prevent major repairs at a later date. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information. Do not use aerosol types of starting aids such as ether.
SEBU8726-03 Operation Section Starting the Engine 5. Repeat step 2 through step 4 if the engine fails to start. Note: After starting, the engine will be held at low speed. The time held at low speed will depend on ambient temperature and time since last run. The procedure is in order to allow the engine systems to stabilize. The engine should not be “raced” in order to speed up the warm-up process. 6.
SEBU8726-03 Operation Section After Starting Engine Improper jump start cable connections can cause an explosion resulting in personal injury. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump start cable ends to contact each other or the engine. Note: If possible, first diagnose the reason for the starting failure. Refer to Troubleshooting, “Engine Will Not Crank and Engine Cranks But Will Not Start” for further information. Make any necessary repairs.
SEBU8726-03 Operation Section Engine Operation Engine Operation i04653132 During the time of elevated fuel pressure, the operator may notice a change in the tone of the engine. The ECM will operate the check at low idle for approximately 5 minutes. Engine Operation Proper operation and maintenance are key factors in obtaining the maximum life and economy of the engine.
SEBU8726-03 Operation Section Diesel Particulate Filter Regeneration For a typical view of the wall flow DPF, refer to this Operation and Maintenance Manual, “Sensors and Electrical Components (Aftertreatment)” Regeneration Indicators Five indicators can be affected by the DPF regeneration. these indicators are, Regeneration Active, DPF, Disable Regeneration, Amber, or Yellow Warning Indicator and Red Stop Indicator. Regeneration Active – This indicator will illuminate during active regeneration.
SEBU8726-03 Operation Section Diesel Particulate Filter Regeneration Table 4 Indicator Operation During passive regeneration no indicator will be illuminated Aftertreatment Indicator Aftertreatment Indica- Warning Indicator tor State Warning Indicator Description State Regeneration Active indicator On Solid None None Action Required Regeneration is activated. None The indicator will stay illuminated during regeneration.
SEBU8726-03 Operation Section Fuel Conservation Practices Service Regeneration The electronic service tool will be required in order to perform a force regeneration. Contact your Perkins distributor or your Perkins dealer. i04018232 Fuel Conservation Practices • Cold engines consume excess fuel. Utilize heat from the jacket water system and the exhaust system, when possible. Keep cooling system components clean and keep cooling system components in good repair.
SEBU8726-03 Operation Section Cold Weather Operation Cold Weather Operation i06024580 Cold Weather Operation Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and the operation of the diesel engine is dependent on the following items: • The type of fuel that is used • The viscosity of the engine oil • Check all rubber parts (hoses, fan drive belts,) weekly. • Check all electrical wiring and connections for any fraying or damaged insulation.
SEBU8726-03 Operation Section Cold Weather Operation Engine Block Heaters • Valves become stuck. Engine block heaters (if equipped) heat the engine jacket water that surrounds the combustion chambers. This heat provides the following functions: • Pushrods may become bent. • Startability is improved. • Warm up time is reduced. An electric block heater can be activated once the engine is stopped. A block heater can be 110 V dc or 240 V dc. The output can be 750/1000W.
SEBU8726-03 Operation Section Fuel and the Effect from Cold Weather Recommendation for Crankcase Breather Protection • Fuel heaters, which may be an OEM option • Fuel line insulation, which may be an OEM option Crankcase ventilation gases can contain a large quantity of water vapor. This water vapor can freeze in cold ambient conditions and can plug or damage the crankcase ventilation system.
SEBU8726-03 Operation Section Fuel Related Components in Cold Weather The location of a primary fuel filter is important in cold weather operation. The primary fuel filter and the fuel supply line are the most common components that are affected by cold fuel. Fuel Heaters Note: The OEM may equip the application with fuel heaters. If this is the case, the temperature of the fuel must not exceed 73 °C (163 °F) at the fuel transfer pump.
SEBU8726-03 Operation Section Engine Stopping Engine Stopping i05784249 After Stopping Engine i04535875 Stopping the Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes. This period will 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. Avoid accelerating the engine prior to shutting it down.
SEBU8726-03 Operation Section After Stopping Engine 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. Loosen the cooling system pressure cap slowly in order to relieve the pressure. • Allow the engine to cool. Check the coolant level. • Check the coolant for correct antifreeze protection and the correct corrosion protection. Add the correct coolant/water mixture, if necessary.
SEBU8726-03 Maintenance Section Refill Capacities Maintenance Section (Table 6, contd) (1) The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM specifications. Enter the value for the capacity of the External System in this row.
SEBU8726-03 Maintenance Section Fluid Recommendations Terminology Certain abbreviations follow the nomenclature of “SAE J754”. Some classifications follow “SAE J183” abbreviations, and some classifications follow the “EMA Recommended Guideline on Diesel Engine Oil”. In addition to Perkins definitions, there are other definitions that will be of assistance in purchasing lubricants.
SEBU8726-03 Maintenance Section Fluid Recommendations • At the specified interval, service the engine. Use new oil and install a new oil filter. • Perform maintenance at the intervals that are specified in the Operation and Maintenance Manual, “Maintenance Interval Schedule”. Oil analysis Some engines may be equipped with an oil sampling valve. If oil analysis is required, the oil sampling valve is used to obtain samples of the engine oil.
SEBU8726-03 Maintenance Section Fluid Recommendations NOTICE Frequently check the specific gravity of the coolant for proper freeze protection or for anti-boil protection.
SEBU8726-03 Maintenance Section Fluid Recommendations Most conventional antifreezes use ethylene glycol. Propylene glycol may also be used. In a 1:1 mixture with water, ethylene and propylene glycol provide similar protection against freezing and boiling. Refer to Table 9 and refer to table 10 . Table 9 Ethylene Glycol Concentration Freeze Protection 50 Percent −36 °C (−33 °F) 60 Percent −51 °C (−60 °F) Perkins recommends a 1:1 mixture of water and glycol.
SEBU8726-03 Maintenance Section Fluid Recommendations Containers of several sizes are available. Consult your Perkins distributor for the part numbers. ELC Cooling System Maintenance Correct additions to the Extended Life Coolant NOTICE Use only Perkins products for pre-mixed or concentrated coolants. Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life.
SEBU8726-03 Maintenance Section Fluid Recommendations • Drain the cooling system into a suitable container. Dispose of the coolant according to local regulations. Flush the system with clean water. Fill the system with the Perkins ELC. • Drain a portion of the cooling system into a suitable container according to local regulations. Then, fill the cooling system with premixed ELC. This procedure should lower the contamination to less than 10 percent.
SEBU8726-03 Maintenance Section Fluid Recommendations • Clean the cooling system whenever the coolant is contaminated or whenever the coolant is foaming.
SEBU8726-03 Maintenance Section Fuel Specification Table 16 "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% Bottoms %Weight 0.
SEBU8726-03 Maintenance Section Fuel Specification (Table 16, contd) (4) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscosity 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.
SEBU8726-03 Maintenance Section Fuel Specification Diesel Fuel Characteristics Density Cetane Number Density is the mass of the fuel per unit volume at a specific temperature. This parameter has a direct influence on engine performance and a direct influence on emissions. This influence determines from a heat output given injected volume of fuel. This parameter is quoted in the following kg/m3 at 15 °C (59 °F). Fuel that has a high cetane number will give a shorter ignition delay.
SEBU8726-03 Maintenance Section Fuel Specification NOTICE The fuels system has been qualified with fuel having lubricity up to 0.52 mm (0.0205 inch) wear scar diameter as tested by “ISO 12156-1”. Fuel with higher wear scar diameter than 0.52 mm (0.0205 inch) will lead to reduced service life and premature failure of the fuel system. Fuel additives can enhance the lubricity of a fuel. Contact your fuel supplier for those circumstances when fuel additives are required.
SEBU8726-03 Maintenance Section Fuel Specification • Crankcase oil fuel dilution can be higher when biodiesel or biodiesel blends are used. This increased level of fuel dilution when using biodiesel or biodiesel blends is related to the typically lower volatility of biodiesel. In-cylinder emissions control strategies utilized in many of the industrial latest engine designs may lead to a higher level of biodiesel concentration in the sump.
SEBU8726-03 Maintenance Section Fuel Specification BTL and HVO fuels are considered to be low carbon fuels as they reduce carbon foot print compared to fossil fuels and are commonly referred to as renewable fuels. These fuels must not be confused with biodiesel FAME which is fundamentally different fuel and is discussed in a separate section in this manual.
SEBU8726-03 Maintenance Section Fuel Specification Note: Perkins fuel cleaner is compatible with existing and U.S. EPA Tier 4 nonroad certified diesel engine emission control catalysts and particulate filters. Perkins fuel system cleaner contains less than 15 ppm of sulfur and is acceptable for use with ULSD fuel. Contamination Control Recommendations for Fuels Fuels of “ISO 18/16/13” cleanliness level or cleaner as dispensed into the engine or application fuel tank should be used.
SEBU8726-03 Maintenance Section Maintenance Recommendations Maintenance Recommendations 2. Wait for 10 minutes. Do not loosen the high pressure fuel lines in order to remove air from the fuel system. i03648938 System Pressure Release Coolant System Engine Oil To relieve pressure from the lubricating system, turn off the engine. i05400894 Welding on Engines with Electronic Controls Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool.
SEBU8726-03 Maintenance Section Welding on Engines with Electronic Controls 4. Disconnect all electronic components from the wiring harnesses. Include the following components: • Electronic components for the driven equipment • ECM • Sensors • Electronically controlled valves • Relays • Aftertreatment ID module NOTICE Do not use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder. Illustration 44 g01075639 Use the example above.
SEBU8726-03 Maintenance Section Severe Service Application 7. Use standard welding practices to weld the materials. i04150276 Severe Service Application Severe service is the application of an engine that exceeds the current published standards for that engine.
SEBU8726-03 Maintenance Section Maintenance Interval Schedule i05325425 Maintenance Interval Schedule When Required “ Engine Air Cleaner Element (Single Element) Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . 97 “ Engine Oil and Filter - Change” . . . . . . . . . . . . . . . . “ Fuel System Primary Filter (Water Separator) Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 105 “ Fuel System Secondary Filter - Replace” . . . . . 107 “ Battery - Replace” . . . . . .
SEBU8726-03 Maintenance Section Maintenance Interval Schedule “ Radiator Pressure Cap - Clean/Replace” . . . . . 112 Every 3000 Service Hours or 2 Years “ Coolant (Commercial Heavy-Duty) - Change” . . 90 Every 4000 Service Hours “ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 87 Every 6000 Service Hours or 3 Years “ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . 93 Every 12 000 Service Hours or 6 Years “ Coolant (ELC) - Change” . . . . . . . . . . . . . . . . . . . . .
SEBU8726-03 Maintenance Section Aftercooler Core - Clean/Test i01807350 Aftercooler Core - Clean/Test (Air-To-Air Aftercooler) The air-to-air aftercooler is OEM installed in many applications. Please refer to the OEM specifications for information that is related to the aftercooler. i02322295 Aftercooler Core - Inspect Note: Adjust the frequency of cleaning according to the effects of the operating environment.
SEBU8726-03 Maintenance Section Battery - Replace 5. Install the new belt, use belt configuration (A). Visually check that the belt is correctly aligned. 6. Turn the screw (2) clockwise in order to tension the belt. Ensure that the link adjuster (7) is at the maximum extension, refer to illustration 46 . 7. Tighten bolt (5), nut, and bolt (6) and tighten nut and bolt (1). Tighten these nuts and bolts to 50 N·m (37 lb ft). 8.
SEBU8726-03 Maintenance Section Battery Electrolyte Level - Check Note: Always recycle a battery. Never discard a battery. Dispose of used batteries to an appropriate recycling facility. Thoroughly rinse the battery case with clean water. i02323088 6. Remove the used battery. 7. Install the new battery. Note: Before the cables are connected, ensure that the battery disconnect switch is in the OFF position. Battery or Battery Cable Disconnect 8.
SEBU8726-03 Maintenance Section Coolant (Commercial Heavy-Duty) - Change i05326349 Coolant (Commercial HeavyDuty) - 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.
SEBU8726-03 Maintenance Section Coolant (ELC) - Change 3. Fill the cooling system with clean water. Install the cooling system filler cap. 4. Start and run the engine at low idle until the temperature reaches 49 to 66 °C (120 to 150 °F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Remove the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator.
SEBU8726-03 Maintenance Section Coolant (ELC) - 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 of the coolant 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.
SEBU8726-03 Maintenance Section Coolant Extender (ELC) - Add NOTICE Dispose of used engine coolant or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Perkins to reclaim the coolant. 4. Maintain the coolant level at the maximum mark that is correct for your application. For information regarding the disposal and the recycling of used coolant, consult your Perkins distributor.
SEBU8726-03 Maintenance Section Coolant Level - Check i05149389 Coolant Level - Check Engines With a Coolant Recovery Tank Note: The cooling system may not have been provided by Perkins. The procedure that follows is for typical cooling systems. Refer to the OEM information for the correct procedures. Check the coolant level when the engine is stopped and cool.
SEBU8726-03 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. 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. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Remove the cooling system filler cap slowly in order to relieve pressure. 2.
SEBU8726-03 Maintenance Section Diesel Particulate Filter - Clean 4. Clean the cooling system filler cap and inspect the gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the filler cap. The correct pressure is stamped on the face of the filler cap. If the filler cap does not retain the correct pressure, install a new filler cap.
SEBU8726-03 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace • Ease of maintenance i02335405 Note: Caution must be used to prevent electrical components from being damaged by excessive water when the engine is cleaned. Pressure washers and steam cleaners should not be directed at any electrical connectors or the junction of cables into the rear of the connectors. Avoid electrical components such as the alternator, the starter, and the ECM.
SEBU8726-03 Maintenance Section Engine Air Precleaner - Check/Clean If the service indicator does not reset easily, or if the yellow core does not latch at the greatest vacuum, the service indicator should be replaced. If the new service indicator will not reset, the hole for the service indicator may be restricted. The service indicator may need to be replaced frequently in environments that are severely dusty.
SEBU8726-03 Maintenance Section Engine Mounts - Inspect 2. If necessary, remove breather pipes on cover (6). Remove nuts (7) and remove cover (6) from housing (1). 4. Install the guard, refer to OEM. 3. Remove circlip (4) and remove the breather element (3) and discard. Engine Mounts - Inspect i02323089 4. Remove the O ring seal (5) from the cover. Install the Breather Element Ensure that all the components are clean and free from damage.
SEBU8726-03 Maintenance Section Engine Oil Sample - Obtain Note: Ensure that the engine is either level or that the engine is in the normal operating position in order to obtain a true level indication. • Engine number Note: After the engine has been switched OFF, wait for 10 minutes in order to allow the engine oil to drain to the oil pan before checking the oil level. • The number of hours that have accumulated since the last oil change 1.
SEBU8726-03 Maintenance Section Engine Oil and Filter - Change Do not drain the engine lubricating oil when the engine is cold. As the engine lubricating oil cools, 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.
SEBU8726-03 Maintenance Section Engine Oil and Filter - Change Vertically Up Oil Filter Illustration 63 g02829378 4. Remove the engine oil level gauge to check the oil level. Maintain the oil level between the MIN mark and MAX mark on the engine oil level gauge. Do not fill the crankcase above the MAX mark. Engine Oil Service Reset Illustration 62 g02596778 (4) Vertically up oil filter Some oil filters may be installed vertically up. Use the same procedure to replace the oil filter.
SEBU8726-03 Maintenance Section Fan Clearance - Check Throttle Control Option Note: Some application the maximum throttle position can before the throttle peddle has reached the stop. The actual maximum position of the throttle must be known before starting the procedure. With the known maximum position the middle position of the throttle can be calculated. The throttle must be positioned in the required positions for the prescribed period to perform an engine oil service reset. 1.
SEBU8726-03 Maintenance Section Fuel System - Prime Illustration 64 g02585058 Typical example Adjustment of the cover will change the clearance (gap) between the edge of the cover and the tip of the fan blade. Ensure that the cover is centralized to the fan. The clearance (A) must be set to 10 ± 1 mm (0.39370 ± 0.03937 inch). i04366913 Fuel System - Prime NOTICE Do not crank the engine continuously for more than 30 seconds.
SEBU8726-03 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 1. Ensure that the fuel system is in working order. Check that the fuel supply valve (if equipped) is in the “ON” position. 2. Operate the hand priming pump. Count the number of operations of the pump. After approximately 80 depression of the pump stop. Note: As the fuel system is primed, the pressure will increase within the fuel system and this increase in pressure can be felt during priming. 3.
SEBU8726-03 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 6. Tighten the vent screw (1) securely . Remove the wiring harness from connection (4). 8. Rotate the filter element counterclockwise and remove the filter element (5). Clean the filter bowl. Install the Element Illustration 66 g03374223 Typical example 7. Using a suitable tool, remove the filter bowl (6). Rotate the filter assembly counterclockwise in order to remove the filter assembly.
SEBU8726-03 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 5. The secondary filter element must be replaced at the same time as the primary filter element. Refer to the Operation and Maintenance Manual , “Fuel System Filter - Replace”. i05326334 Fuel System Primary Filter/ Water Separator - Drain Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
SEBU8726-03 Maintenance Section Fuel System Secondary Filter - Replace Refer to Systems Operation, Testing, and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. Remove the Element 1. Turn the fuel supply valve (if equipped) to the OFF position before performing this maintenance. 2. Place a suitable container under the fuel filter in order to catch any fuel that might spill.
SEBU8726-03 Maintenance Section Fuel Tank Water and Sediment - Drain 2. Lubricate the O ring seal (6) with clean engine oil. Do NOT fill the filter bowl (2) with fuel before the filter assembly is installed. Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve. 3. Do not use a tool in order to install the filter assembly. Tighten the assembly by hand. Install the filter bowl (2) and align with your temporary Marks.
SEBU8726-03 Maintenance Section Hoses and Clamps - Inspect/Replace Inspect all hoses for leaks that are caused by the following conditions: • Cracking • Softness • Loose clamps Replace hoses that are cracked or soft. Tighten any loose clamps.
SEBU8726-03 Maintenance Section Oxygen Sensor - Replace 10. Start the engine. Inspect the cooling system for leaks. Inspect the radiator for these items: Damaged fins, corrosion, dirt, grease, insects, leaves, oil and other debris. Clean the radiator, if necessary. i05324852 Oxygen Sensor - Replace Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
SEBU8726-03 Maintenance Section Radiator Pressure Cap - Clean/Replace i03639888 Radiator Pressure Cap - Clean/ Replace 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. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
SEBU8726-03 Maintenance Section Walk-Around Inspection 2. Remove the air intake pipe (1). Visually inspect the piping for the presence of oil. A small amount oil will be expected, this oil is due to the breather system design. Clean the interior of the pipe in order to prevent dirt from entering during reassembly. 3. Check for obvious heat discoloration of the turbocharger. Check for any loose bolts or any missing bolts. Check for damage to the oil supply line (3) and the oil drain line (2).
SEBU8726-03 Maintenance Section Water Pump - Inspect 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. • Check the condition of the gauges. Replace any gauges that are cracked. Replace any gauge that cannot be calibrated.
SEBU8726-03 Warranty Section Warranty Information Warranty Section Warranty Information i05328140 Emissions Warranty Information • EPA Protection Agency • CARB United States Environmental California Air Resources Board Note: The warranty of the engine applies to engines that are operated within the areas of the world where the following regulations apply: US EPA Tier 4 Interim, EU Stage IIIB or Japanese MLIT Step 4.
SEBU8726-03 Reference Information Section Reference Materials Reference Information Section www.perkins.com NOTICE Dependant upon engine type and application. Reference Materials i04224089 Engine Protection Plans (Extended Service Contract) Extended Service Contracts-purchased in minutes, protected for years. Extended Service Contracts (ESC) protect you from the stress that unexpected repair work brings to your life by covering the cost of getting your engine up and running again.
SEBU8726-03 Index Section Index A After Starting Engine ....................................... 56 After Stopping Engine ..................................... 65 Aftercooler Core - Clean/Test (Air-To-Air Aftercooler) .................................................... 87 Aftercooler Core - Inspect ............................... 87 Alarms and Shutoffs ........................................ 34 Alternator - Inspect .......................................... 87 Alternator and Fan Belts - Replace ...
SEBU8726-03 Index Section Engine Oil Level - Check................................. 99 Engine Oil Sample - Obtain........................... 100 Obtain the Sample and the Analysis ......... 100 Engine Operation ............................................ 57 System Check.............................................. 57 Engine Operation with Active Diagnostic Codes ............................................................ 50 Engine Operation with Intermittent Diagnostic Codes ......................
SEBU8726-03 Index Section Every 3000 Service Hours or 2 Years ......... 86 Every 4000 Service Hours........................... 86 Every 50 Service Hours or Monthly ............. 85 Every 50 Service Hours or Weekly.............. 85 Every 500 Service Hours ............................. 85 Every 500 Service Hours or 1 Year ............. 85 Every 6000 Service Hours or 3 Years ......... 86 Every Week ................................................. 85 When Required........................................
SEBU8726-03 Index Section High Pressure Fuel Lines ...........................114 Inspect the Engine for Leaks and for Loose Connections ..............................................113 Warranty Information......................................115 Warranty Section ............................................115 Water Pump - Inspect.....................................114 Welding on Engines with Electronic Controls .........................................................
Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual.
SEBU8726 ©2016 Perkins Engines Company Limited All Rights Reserved 122 June 2016 This document has been printed from SPI2.
