Perkins 854E-E34TA Operation And Maintenance Manual
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Perkins 854E-E34TA Operation And Maintenance Manual

Industrial engines
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SEBU8726-02
July 2013
Operation and
Maintenance
Manual
854E-E34TA and 854F-E34T Industrial
Engines
JR (Engine)
JS (Engine)
JT (Engine)

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Summary of Contents for Perkins 854E-E34TA

  • Page 1 SEBU8726-02 July 2013 Operation and Maintenance Manual 854E-E34TA and 854F-E34T Industrial Engines JR (Engine) JS (Engine) JT (Engine)

  • Page 2: Important Safety Information

    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.

  • Page 3: Table Of Contents

    SEBU8726 Table of Contents Table of Contents Maintenance Section Refill Capacities..........66 Foreword............4 Maintenance Recommendations....80 Safety Section Maintenance Interval Schedule ...... 83 Safety Messages..........5 Warranty Section General Hazard Information ......6 Warranty Information ....

  • Page 4: Foreword

    Operation and Maintenance Manual except for the Operation interval and the maintenance items in that interval. Major repairs should only be carried out by Perkins Operating techniques outlined in this manual are authorized personnel. Your Perkins dealer or your basic. They assist with developing the skills and...

  • Page 5: Safety Section

    Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Perkins distributor can provide new warning signs. Universal Warning...

  • Page 6: General Hazard Information

    SEBU8726 Safety Section General Hazard Information Illustration 2 g02582556 Typical example • Tampering with the engine installation or tampering i03566024 with the OEM supplied wiring can be dangerous. General Hazard Information 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.

  • Page 7: Pressurized Air And Water

    SEBU8726 Safety Section General Hazard Information • The engine is stopped. Ensure that the engine can Use caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts not be started. or nuts that are located at opposite ends of the cover plate or the device.

  • Page 8: Asbestos Information

    Perkins replacement parts that are shipped from or personal injury may occur. Refer to the OEM Perkins are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. information for any procedures that are required to Use the following guidelines when you handle any relieve the hydraulic pressure.

  • Page 9: Burn Prevention

    SEBU8726 Safety Section Burn Prevention • Never use compressed air for cleaning. i04289958 Burn Prevention • Avoid brushing materials that contain asbestos. • Avoid grinding materials that contain asbestos. Do not touch any part of an operating engine system. • Use a wet method in order to clean up asbestos The engine, the exhaust, and the engine materials.

  • Page 10: Fire Prevention And Explosion Prevention

    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.
  • Page 11 SEBU8726 Safety Section 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.

  • Page 12: Crushing Prevention And Cutting Prevention

    Do not install any lines that are i04016709 damaged. Mounting and Dismounting Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for replacement parts. Replace the parts if any of the following conditions Do not climb on the engine or the engine are present: aftertreatment.
  • Page 13 SEBU8726 Safety Section High Pressure Fuel Lines Illustration 11 g02315653 (1) High-pressure line (3) High-pressure line (5) High-pressure fuel manifold (rail) (2) High-pressure line (4) High-pressure line (6) Fuel transfer line that is high pressure The high-pressure fuel lines are the fuel lines that are If you inspect the engine in operation, always use the between the high-pressure fuel pump and the high- proper inspection procedure in order to avoid a fluid...

  • Page 14: Before Starting Engine

    SEBU8726 Safety Section Before Starting Engine Start the engine from the operators compartment or i02813489 from the engine start switch. Before Starting Engine Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Before the initial start-up of an engine that is new, Section.

  • Page 15: Grounding Practices

    SEBU8726 Safety Section Electrical System 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. If the starting motor is not equipped with a negative “−”...

  • Page 16: Engine Electronics

    SEBU8726 Safety Section Engine Electronics The Engine Monitoring package can vary for different i04346349 engine models and different engine applications. Engine Electronics However, the monitoring system and the engine monitoring control will be similar for all engines. 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.

  • Page 17: Product Information Section

    SEBU8726 Product Information Section Model View Illustrations Product Information Section General Information i05297867 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 and Aftertreatment Illustration 14 g03367500 Typical example...
  • Page 18 SEBU8726 General Information Model View Illustrations Illustration 15 g03367502 Typical example (13) Secondary fuel filter (15) Oil level gauge (Dipstick) (17) Valve mechanism cover (14) Oil filter (16) High-pressure fuel pump...
  • Page 19 SEBU8726 General Information Model View Illustrations Illustration 16 g03367547 (18) Rear lifting eyes (21) Oil filler cap (24) Coolant outlet connection (19) Front lifting eye (22) Belt (25) Air inlet connection (20) Crankcase breather (23) Coolant pump The oil filler cap (21) can be located on the valve mechanism cover.
  • Page 20 SEBU8726 General Information Model View Illustrations Off Engine Parts Illustration 17 g03367521 (26) Fuel priming pump (28) Differential pressure sensor (30) Relay for glow plugs (27) Primary fuel filter (29) Electronic control module...
  • Page 21 SEBU8726 General Information 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.

  • Page 22: Product Description

    • Four stroke cycle Product Description • Turbocharged • Turbocharged charge cooled The Perkins 854F-E34T and the 854E-E34TA • Wall Flow Diesel Particulate Filter or Through-Flow industrial engines has the following characteristics. Diesel Particulate Filter Engine Specifications Note: The front end of the engine is opposite the flywheel end of the engine.

  • Page 23: Electronic Engine Features

    There are three different engine types and two different types of aftertreatment. The 854E-E34TA is Engine Cooling and Lubrication turbocharged, charge cooled engine, with a wall flow Diesel Particulate Filter (DPF). The letters JR will be The cooling system and lubrication system consists on the identification plate.

  • Page 24: Engine Service Life

    Therefore, the defects are NOT covered under the Perkins warranty. Aftertreatment System The aftertreatment system is approved for use by Perkins . In order to be emission-compliant only the approved Perkins aftertreatment system must be used on a Perkins engine.

  • Page 25: Product Identification Information

    Product Identification Serial Number location Information i04725109 Plate Locations and Film Locations (Engine) Perkins engines are identified by an engine serial number. An example of an engine number is JR*****L000001V. ***** The list number for the engine The type of engine...
  • Page 26 SEBU8726 Product Identification Information Plate Locations and Film Locations Illustration 22 g02826736 Typical example On a stressed cylinder block the serial number is located in position (3). The engine serial number is stamped on the emissions plate.

  • Page 27: Plate Locations And Film Locations

    SEBU8726 Product Identification Information Plate Locations and Film Locations i05328112 Plate Locations and Film Locations (Aftertreatment) Wall Flow Diesel Particulate Filter (DPF) Illustration 23 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).

  • Page 28: Through-Flow Diesel Particulate Filter (Dpf)

    (1) Serial numbers on main body (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. i05328174...

  • Page 29: Reference Information

    SEBU8726 Product Identification Information Reference Information Illustration 25 g02646428 Typical example Engine Aftertreatment System i05324886 Reference Information 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.

  • Page 30: Operation Section

    The engine must be stored in a water proof building. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of −36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature and humidity.

  • Page 31: Open Cooling System

    Maintenance Manual, “Fluid recommendations”. 4. Remove the drive belt from the engine. Sealed Coolant System Ensure that the cooling system is filled with Perkins ELC, or an antifreeze that meets ASTM D6210 specification. Open Cooling System Ensure that all cooling drain plugs have been opened.

  • Page 32: Features And Controls

    Determine and correct the cause of any significant NOTICE change in the readings. Consult your Perkins distributor for assistance. To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious Some engine applications are equipped with Indicator damage to the engine.

  • Page 33: Indicator Lamps

    SEBU8726 Features and Controls Monitoring System Indicator Lamps • Shutdown lamp • Warning lamp • Wait to start lamp • Low oil pressure lamp (On solid) and engine oil reset lamp (Flashing) For information, refer to this manual, “Monitoring System (Table for the Indicator Lamps)” for the sequence of operation of the shutdown lamp and the warning lamp.
  • Page 34 SEBU8726 Features and Controls Monitoring System Table 2 Warning Shutdown Lamp State Description of the Indication Engine Status Operator Action Indicator Indicator Indicator Check When the keyswitch is moved to the The keyswitch is in the ON If any of the indicators ON position, the lamps will illumi- position but the engine has will not illuminate during...

  • Page 35: Monitoring System

    SEBU8726 Features and Controls Monitoring System Programmable Options and i04317185 Systems Operation Monitoring System If the Warning/Derate/Shutdown mode has been selected and the warning indicator activates, bring the engine to a stop whenever possible. De- If the Shutdown mode has been selected and the pending on the application, special precautions warning indicator activates, engine shutdown should be taken to avoid personal injury.
  • Page 36 Maintenance Manual, “Monitoring System (Table for Indicator Lamps)”. For each of the programmed modes, refer to Troubleshooting Guide, “Indicator Lamps” for more information on Indicator Lamps. For more information or assistance for repairs, consult your Perkins distributor or your Perkins dealer. i04348489 Overspeed • ECM Electronic Control Module •...

  • Page 37: Sensors And Electrical Components

    SEBU8726 Features and Controls Sensors and Electrical Components i05325438 Sensors and Electrical Components Full Engine Views Illustration 27 g03373765 Typical example (1) 10 Pin and 62 pin connector (4) Primary speed/timing sensor (crankshaft (6) Fuel metering valve (2) Fuel temperature sensor position sensor) (3) Oil pressure switch (5) Water in fuel switch...
  • Page 38 SEBU8726 Features and Controls Sensors and Electrical Components Illustration 28 g02477200 Typical example (7) Fuel manifold (rail) pressure sensor (9) Secondary speed/timing sensor (11) Coolant temperature sensor (8) Electronic control module (camshaft position sensor) (12) Intake throttle valve (10) Alternator...
  • Page 39 SEBU8726 Features and Controls Sensors and Electrical Components Illustration 29 g02529496 Typical example (13) Inlet manifold pressure and temperature (15) Exhaust pressure sensor (18) Oxygen sensor sensor. (16) Waste gate regulator (19) Control valve for the NOx reduction (14) Exhaust temperature sensor connection (17) Starting motor system Note: Item (13), lower powered engines have...
  • Page 40 SEBU8726 Features and Controls Sensors and Electrical Components Engine View Low Power with Separate Inlet Pressure and Inlet Temperature Illustration 30 g03373789 Typical example (13 A) Inlet pressure sensor (13 B) Inlet temperature sensor...
  • Page 41 SEBU8726 Features and Controls Sensors and Electrical Components Location Views Illustration 31 g03373767 Typical example (1) 10 Pin and 62 pin connector (4) Primary speed/timing sensor (crankshaft (6) Fuel metering valve (2) Fuel temperature sensor position sensor) (3) Oil pressure switch (5) Water in fuel switch...
  • Page 42 SEBU8726 Features and Controls Sensors and Electrical Components Illustration 32 g02529820 Typical example (7) Fuel manifold (rail) pressure sensor (9) Secondary speed/timing sensor (11) Coolant temperature sensor (8) Electronic control module (camshaft position sensor) (12) Intake throttle valve (10) Alternator Note: The location of item (8) the engine electronic control module will depend on the application.
  • Page 43 SEBU8726 Features and Controls Sensors and Electrical Components Illustration 33 g02529821 Typical example (13) Inlet manifold pressure and temperature (14) Exhaust temperature sensor connection (15) Exhaust pressure sensor sensor. (A) Exhaust temperature sensor (16) Waste gate regulator...
  • Page 44 SEBU8726 Features and Controls Sensors and Electrical Components Illustration 34 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.
  • Page 45 SEBU8726 Features and Controls Sensors and Electrical Components Separate Inlet Pressure and Inlet Temperature Views Illustration 35 g03373791 Typical example (13 A) Intake manifold pressure sensor (13 B) Intake manifold temperature sensor...
  • Page 46 SEBU8726 Features and Controls Sensors and Electrical Components Engine Option or Parts that are Supplied Loose Illustration 36 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.
  • Page 47 SEBU8726 Features and Controls Sensors and Electrical Components Wall Flow Aftertreatment Illustration 37 g03373851 Typical example (1) Diesel oxidation catalyst temperature (3) Inlet connection for the differential (4) Outlet connection for the differential sensor pressure sensor pressure sensor (2) Diesel particulate filter (DPF) temperature (5) Oxygen sensor sensor...

  • Page 48: Through Flow Aftertreatment

    SEBU8726 Features and Controls Sensors and Electrical Components Through Flow Aftertreatment Illustration 38 g03373872 Typical example (1) Diesel oxidation catalyst (DOC) (2) Temperature sensor after DOC (3) Oxygen sensor temperature sensor Differential Pressure sensor Illustration 39 g02477086 Typical example (1) Differential pressure sensor The location of the differential pressure sensor will depend on the application.

  • Page 49: Engine Diagnostics

    The system provides the capability of Fault Logging. When the Electronic Control Module (ECM) generates an active diagnostic code, the code will be Perkins electronic engines have the capability to logged in the memory of the ECM. The codes that perform a self-diagnostics test. When the system...

  • Page 50: Configuration Parameters

    SEBU8726 Engine Diagnostics 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.
  • Page 51 SEBU8726 Engine Diagnostics Configuration Parameters (Table 3, contd) 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...
  • Page 52 SEBU8726 Engine Diagnostics Configuration Parameters (Table 3, contd) Throttle #2 Initial Lower Position 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...

  • Page 53: Engine Starting

    SEBU8726 Engine Starting Before Starting Engine Engine Starting i05365825 Cold Weather Starting i03648917 Before Starting Engine ce and other Do not use aerosol types of starting aids such as periodic maintenance before the engine is started. ether. Such use could result in an explosion and Inspect the engine compartment.

  • Page 54: Starting The Engine

    SEBU8726 Engine Starting Starting the Engine 4. Allow the keyswitch to return to the RUN position Note: During the key on, the indicator lamps will be illuminated for 2 seconds in order to check lamp after the engine starts. operation. If any of the lamps do not illuminate, check 5.

  • Page 55: After Starting Engine

    SEBU8726 Engine Starting After Starting Engine Note: If it is possible, first diagnose the reason for the After jump starting, the alternator may not be able to fully recharge batteries that are severely discharged. starting failure. Refer to Troubleshooting, “Engine Will The batteries must be replaced or charged to the Not Crank and Engine Cranks But Will Not Start”...

  • Page 56: Engine Operation

    SEBU8726 Engine Operation Engine Operation Engine Operation i04690175 Diesel Particulate Filter i04653132 Regeneration Engine Operation Regeneration Proper operation and maintenance are key factors in obtaining the maximum life and economy of the Regeneration is the removal of soot from the Diesel engine.

  • Page 57: Modes Of Regeneration

    SEBU8726 Engine Operation Diesel Particulate Filter Regeneration Regeneration System Warning Regeneration Active – This indicator will illuminate during active regeneration. Indicators The indicator shows that elevated exhaust temperatures are possible. The indicator Some applications may also have an audible warning will be turned off when regeneration is complete.
  • Page 58 Red indicator On Solid indicates that the engine you must contact your (STOP) has continued to be oper- Perkins distributor or ated while a regeneration your Perkins dealer. is required. Your dealer or distributor The engine will be derated will need to perform a serv- and the engine should be ice level regeneration.

  • Page 59: Fuel Conservation Practices

    Systems Operation, Testing and Adjusting, “V-Belt The electronic service tool will be required in order to Test” for further information. perform a force regeneration. Contact your Perkins distributor or your Perkins dealer. • Ensure that all of the connections of the hoses are tight.

  • Page 60: Cold Weather Operation

    • The cooling system and the lubrication system for Perkins Diesel Engines can operate effectively in the engine do not lose heat immediately upon cold weather. During cold weather, the starting and shutdown.

  • Page 61: Viscosity Of The Engine Lubrication Oil

    A block heater can be 110 V dc or • Pushrods may become bent. 240 V dc. The output can be 750/1000W. Consult your Perkins dealer or your Perkins distributor for • Other damage to valve train components can more information.

  • Page 62: Fuel Related Components In Cold Weather

    The coolant then returns to the cylinder Note: Only use grades of fuel that are recommended block via an internal passage that bypasses the valve by Perkins . Refer to this Operation and Maintenance of the coolant temperature regulator. This return Manual, “Fluid Recommendations”.

  • Page 63: Fuel Filters

    SEBU8726 Cold Weather Operation Fuel Related Components in Cold Weather Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank.

  • Page 64: Engine Stopping

    SEBU8726 Engine Stopping Stopping the Engine Engine Stopping i03648931 After Stopping Engine i04535875 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 ac-...
  • Page 65 SEBU8726 Engine Stopping After Stopping Engine • 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. • Perform all required periodic maintenance on all driven equipment.

  • Page 66: Maintenance Section

    Total Cooling Diesel Fuel Requirements System. Table 6 Perkins is not in a position to continuously evaluate and monitor all worldwide distillate diesel fuel Engine specifications that are published by governments and Refill Capacities technological societies.
  • Page 67 SEBU8726 Refill Capacities Fluid Recommendations NOTICE The footnotes are of the key part Perkins Specifica- tion for Distillate Diesel Fuel Table. Read ALL of the footnotes. Table 7 Perkins Specification for Distillate Diesel Fuel Property UNITS Requirements ASTMTest ISOTest Aromatics...
  • Page 68 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, significantly...

  • Page 69: Diesel Fuel Characteristics

    “EU Off Road Diesel fuel. Acceptable from 2011 MUST have less than 10 PPM sulfur level” 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.
  • Page 70 Protection Agency (EPA) and European Certification when fuel additives are required. Your fuel supplier fuels. Perkins does not certify engines on any other can make recommendations for additives to use, and fuel. The user of the engine has the responsibility of for the proper level of treatment.
  • Page 71 • Perkins recommend the use of oil analysis in order to check the quality of the engine oil if Water accelerates microbial contamination and biodiesel fuel is used. Ensure that the level of growth.

  • Page 72: General Lubricant Information

    Perkins . If biodiesel or biodiesel blends of fuel are to be used, Perkins require the use of Perkins fuel cleaner. The use of the fuel is in order to remove deposits within the fuel system that is created with the use of biodiesel.

  • Page 73: Engine Oil

    Recommended oil viscosities can be Note: These engine oils are not approved by found in this publication, “Fluid Recommendations/ Perkins and these engine oils must not be used: Engine Oil” topic (Maintenance Section). CC, CD, CD-2, CF-4, CG-4, CH-4 and CI-4.

  • Page 74: General Coolant Information

    An infrared analysis is used to compare the properties of new oil to the Perkins does not recommend the use of aftermarket additives in oil. It is not necessary to use aftermarket properties of the used oil sample. This analysis...
  • Page 75 SEBU8726 Refill Capacities Fluid Recommendations Table 10 NOTICE Acceptable Water If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system Property Maximum Limit must be either protected to the lowest outside temper- ature or drained completely to prevent damage.

  • Page 76: Coolant Recommendations

    However, ELC diesel engines: contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite. Perkins ELC has Preferred – Perkins ELC been formulated with the correct amount of these additives in order to provide superior corrosion protection for all metals in engine cooling systems.

  • Page 77: Elc Cooling System Maintenance

    Do not use standard supplemental coolant additive (SCA). the cooling system with clean water. When using Perkins ELC, do not use standard SCA's 6. Fill the cooling system with clean water and or SCA filters. operate the engine until the engine is warmed to 49°...
  • Page 78 9. Fill the cooling system with the Perkins Premixed ELC. Check the antifreeze (glycol concentration) in order to ensure adequate protection against boiling or freezing. Perkins recommends the use of a ELC Cooling System Contamination refractometer for checking the glycol concentration.
  • Page 79 SEBU8726 Refill Capacities Fluid Recommendations Additions of SCA are based on the results of the test. The size of the cooling system determines the amount of SCA that is needed. Use the equation that is in Table 16 to determine the amount of SCA that is required, if necessary: Table 16 Equation For Adding The SCA To The Heavy-Duty Coolant For...

  • Page 80: Maintenance Recommendations

    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.
  • Page 81 SEBU8726 Maintenance Recommendations Welding on Engines with Electronic Controls 3. Disconnect the negative battery cable from the battery. If a battery disconnect switch is provided, open the switch. 4. Disconnect all electronic components from the wiring harnesses. Include the following components: •...

  • Page 82: Severe Service Application

    • The temperature of the fluid in the engine Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined parameters. Severe service operation can accelerate component wear.

  • Page 83: Maintenance Interval Schedule

    SEBU8726 Maintenance Recommendations Maintenance Interval Schedule “Fuel System Primary Filter (Water Separator) i05325425 Element - Replace”..........102 Maintenance Interval Schedule “Fuel System Secondary Filter - Replace” ... 104 “Radiator - Clean” ..........108 When Required Every 1000 Service Hours “Battery - Replace”...........85 “Water Pump - Inspect”..........111 “Battery or Battery Cable - Disconnect”....86 Every 1500 Service Hours...

  • Page 84: Aftercooler Core - Inspect

    Aftercooler Core - Clean/Test Alternator - Inspect (Air-To-Air Aftercooler) Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose The air-to-air aftercooler is OEM installed in many connections and correct battery charging. Check the applications. Please refer to the OEM specifications ammeter (if equipped) during engine operation in for information that is related to the aftercooler.

  • Page 85: Battery - Replace

    SEBU8726 Maintenance Recommendations 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 45 .

  • Page 86: Battery Or Battery Cable - Disconnect

    SEBU8726 Maintenance Recommendations Battery Electrolyte Level - Check 5. Disconnect the POSITIVE “+” cable from the • Use a solution of 0.1 kg (0.2 lb) baking soda POSITIVE “+” battery terminal. and 1 L (1 qt) of clean water. • Use a solution of ammonium hydroxide . Note: Always recycle a battery.

  • Page 87: Coolant (Commercial Heavy-Duty) - Change

    The full distilla- tion procedure is the only method acceptable by Per- kins to reclaim the coolant. For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor. Flush...

  • Page 88: Coolant (Elc) - Change

    SEBU8726 Maintenance Recommendations Coolant (ELC) - Change 1. Flush the cooling system with clean water in order to remove any debris. 2. Install the drain plug on the engine. Close the drain cock or install the drain plug on the radiator. NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute, in order to avoid air locks.
  • Page 89 Drain For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor. Flush Pressurized System: Hot coolant can cause seri- ous burns.

  • Page 90: Coolant Extender (Elc) - Add

    4. Maintain the coolant level at the maximum mark Coolant Extender (ELC) - Add that is correct for your application. In order for Perkins ELC to achieve 12000 hours an extender must be added at 6000 hours. For a suitable extender, contact your Perkins dealer or Perkins...

  • Page 91: 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.

  • Page 92: Cooling System Supplemental Coolant Additive (Sca) - Test/Add

    SEBU8726 Maintenance Recommendations Cooling System Supplemental Coolant Additive (SCA) - Test/Add Add the SCA, If Necessary NOTICE Pressurized System: Hot coolant can cause seri- Do not exceed the recommended amount of supple- ous burns. To open the cooling system filler cap, mental coolant additive concentration.

  • Page 93: Engine - Clean

    SEBU8726 Maintenance Recommendations Diesel Particulate Filter - Clean 4. Clean the cooling system filler cap and inspect the Note: Only the wall flow type of aftertreatment requires a service period, in order to remove the ash. gasket. If the gasket is damaged, discard the old The wall flow aftertreatment uses active regeneration filler cap and install a new filler cap.

  • Page 94: Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace

    SEBU8726 Maintenance Recommendations Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace • Easy detection of fluid leaks i02335405 Engine Air Cleaner Service • Maximum heat transfer characteristics Indicator - Inspect • Ease of maintenance Note: Caution must be used in order to prevent electrical components from being damaged by Some engines may be equipped with a different excessive water when the engine is cleaned.

  • Page 95: Engine Air Precleaner - Check/Clean

    SEBU8726 Maintenance Recommendations Engine Air Precleaner - Check/Clean Engine Breather 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 NOTICE service indicator will not reset, the hole for the service Ensure that the engine is stopped before any servic- indicator may be restricted.

  • Page 96: Engine Oil Level - Check

    (3) and discard. Note: The engine mounts may not have been supplied by Perkins . Refer to the OEM information 4. Remove the O ring seal (5) from the cover. for further information on the engine mounts and the correct bolt torque.

  • Page 97: Engine Oil Sample - Obtain

    Perkins recommends using a sampling valve in order to obtain oil samples. The quality and the consistency Hot oil and hot components can cause personal of the samples are better when a sampling valve is injury.

  • Page 98: Replace The Oil Filter

    Use of an oil filter that is not recommended draining cold oil. Drain the oil pan with the engine by Perkins could result in severe damage to the en- stopped. Drain the oil pan with the oil warm. This...

  • Page 99: Engine Oil Service Reset

    Some applications may have other methods in order to perform an engine oil service reset. For assistance mote filter system, follow the OEM or the filter manu- with the engine oil service reset contact your Perkins factures recommendations. Under filling or over filling distributor, or your OEM.

  • Page 100: Fan Clearance - Check

    SEBU8726 Maintenance Recommendations Fan Clearance - Check Throttle Control Option 5. Return the multi-state switch to position 0 for more than 15 seconds, but less than 30 seconds Note: Some application the maximum throttle 6. Turn the multi-state switch to position 1 for more position can before the throttle peddle has reached the stop.

  • Page 101: Fuel System - Prime

    SEBU8726 Maintenance Recommendations Fuel System - Prime Illustration 62 g02585058 Typical example Adjustment of the cover will change the clearance NOTICE (gap) between the edge of the cover and the tip of the Do not crank the engine continuously for more than fan blade.

  • Page 102: Fuel System Primary Filter (Water Separator)

    SEBU8726 Maintenance Recommendations Fuel System Primary Filter (Water Separator) Element - Replace 1. Ensure that the fuel system is in working order. Note: Refer to Systems Operation, Testing, and Adjusting, “Cleanliness of Fuel System Check that the fuel supply valve (if equipped) is in Components”...

  • Page 103: Install The Element

    SEBU8726 Maintenance Recommendations Fuel System Primary Filter (Water Separator) Element - Replace 6. Tighten the vent screw (1) securely . Remove the wiring harness from connection (4). Illustration 65 g03374224 Typical example Illustration 64 g03374223 1. Locate the thread in the filter element (8) onto the Typical example threads (9).

  • Page 104: Fuel System Primary Filter/Water Separator - Drain

    SEBU8726 Maintenance Recommendations Fuel System Primary Filter/Water Separator - Drain 3. Install a suitable tube onto drain (3). Open the drain i05326334 valve (2). Rotate the drain valve counterclockwise. Fuel System Primary Filter/ Two full turns are required. Loosen vent screw (1). Water Separator - Drain Note: Two complete rotations of the valve will release the valve from the filter element.
  • Page 105 SEBU8726 Maintenance Recommendations Fuel System Secondary Filter - Replace Illustration 67 g02522536 Illustration 68 g02522538 Typical example Typical example 3. Make a temporary Mark (A) across the filter before 7. Rotate the filter element counterclockwise and the assembly is removed. Install a suitable tube remove the filter element (5).

  • Page 106: Hoses And Clamps - Inspect/Replace

    SEBU8726 Maintenance Recommendations Fuel Tank Water and Sediment - Drain Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the 3. Do not use a tool in order to install the filter drain valve.

  • Page 107: Replace The Hoses And The Clamps

    SEBU8726 Maintenance Recommendations Hoses and Clamps - Inspect/Replace Inspect all hoses for leaks that are caused by the following conditions: Pressurized System: Hot coolant can cause seri- • Cracking ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system •...

  • Page 108: Radiator - Clean

    “comb”. Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps and seals. Make repairs, if necessary. 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.

  • Page 109: Starting Motor - Inspect

    Refer to the Systems Operation, Testing and Adjusting Manual, “Electric Starting System - Test” for more information on the checking procedure and for specifications or consult your Perkins dealer or your Perkins distributor for assistance. Illustration 71 g02603804...

  • Page 110: Walk-Around Inspection

    Refer to Disassembly and Assembly, “Water Pump - housing. Ensure that all clamps are installed Remove and Install”. For more information, consult your Perkins dealer or your Perkins distributor. correctly and that all clamps are tightened securely. For more information, refer to Systems •...

  • Page 111: Water Pump - Inspect

    SEBU8726 Maintenance Recommendations Water Pump - Inspect High Pressure Fuel Lines i04406817 Water Pump - Inspect Contact with high pressure fuel may cause fluid A failed water pump may cause severe engine penetration and burn hazards. High pressure fuel overheating problems that could result in the following spray may cause a fire hazard.

  • Page 112: Warranty Section

    For a full warranty statement contact your Perkins dealer or your Perkins distributor. For customers that have a valid user name and password, for perkins.com. Login then go to TIPSS, and the warranty information can be accessed. Maintenance Recommendations Efficiency of the emission control and the engine...

  • Page 113: Reference Information Section

    Why buy an Extended Service Contract? 1. No surprises - total protection from unexpected repair cost (parts, labor, and travel). 2. Enjoy longer lasting product support from Perkins global network. 3. Genuine Perkins parts ensure continued engine performance. 4. Highly trained technicians carry out all repairs.

  • Page 114: Index

    SEBU8726 Index Section Index Cooling System Supplemental Coolant Additive (SCA) - Test/Add ......92 After Starting Engine........55 Add the SCA, If Necessary ......92 After Stopping Engine........64 Test for SCA Concentration ......92 Aftercooler Core - Clean/Test (Air-To-Air Crushing Prevention and Cutting Prevention ..
  • Page 115 SEBU8726 Index Section Engine Operation..........56 Install the Element ........105 System Check..........56 Remove the Element ......... 104 Engine Operation with Active Diagnostic Fuel Tank Water and Sediment - Drain..106 Codes ............49 Drain the Water and the Sediment..... 106 Engine Operation with Intermittent Fuel Storage Tanks ........
  • Page 116 Stopping the Engine ........64 Serial Number location......... 25 System Pressure Release....... 80 Product Description ......... 22 Coolant System..........80 Aftermarket Products and Perkins Engines Engine Oil ............ 80 ..............24 Fuel System ..........80 Electronic Engine Features......23 Engine Cooling and Lubrication....23 Engine Diagnostics ........
  • Page 117 SEBU8726 Index Section Inspect the Engine for Leaks and for Loose Connections ..........110 Warranty Information ........112 Warranty Section ..........112 Water Pump - Inspect ........111 Welding on Engines with Electronic Controls .. 80...
  • Page 118 SEBU8726 Index Section...
  • Page 119 ©2013 Perkins Engines Company Limited All Rights Reserved...

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