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Perkins SEBU9068-03 Operation And Maintenance Manual

Industrial engine
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SEBU9068-03 (en-us)
December 2020
Operation and
Maintenance
Manual
854F-E34TA Industrial Engine
JU (Engine)

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Summary of Contents for Perkins SEBU9068-03

  • Page 1 SEBU9068-03 (en-us) December 2020 Operation and Maintenance Manual 854F-E34TA Industrial Engine JU (Engine)
  • Page 2 If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

  • Page 3: Table Of Contents

    SEBU9068-03 Table of Contents Table of Contents Maintenance Section Refill Capacities..........63 Foreword ............4 Maintenance Recommendations ....78 Safety Section Maintenance Interval Schedule....... 81 Safety Messages..........6 Warranty Section General Hazard Information......6 Warranty Information........115 Burn Prevention..........11 Reference Information Section Fire Prevention and Explosion Prevention..

  • Page 4: Foreword

    State of arises regarding your engine, or this manual, please California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins distributor for the latest available information. and other reproductive harm. WARNING – This product can...
  • Page 5 Perkins distributor offers various options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options.

  • Page 6: Safety Section

    Replace any warning sign that is damaged or Typical example 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 i08312804 provide new warning signs. General Hazard Information...
  • Page 7 SEBU9068-03 Safety Section General Hazard Information • Tampering with the engine installation or • Do not attempt any repairs or any adjustments to tampering with the OEM supplied wiring can be the engine while the engine is operating. dangerous. Personal injury, death and/or engine •...
  • Page 8 Do not disassemble any hydraulic • Perkins recommend that you do not stand next to components or parts until pressure has been relieved an exposed running engine unless it is necessary or personal injury may occur.
  • Page 9 Hexavalent Chromium Perkins equipment and replacement parts comply with applicable regulations and requirements where originally sold. Perkins recommends the use of only genuine Perkins replacement parts. Hexavalent chromium has occasionally been detected on exhaust and heat shield systems on Perkins engines.
  • Page 10 • Wear an approved respirator if there is no other good hygiene, and adhering to safe work practices way to control the dust. when handling the equipment or parts. Perkins also recommends the following: • Comply with applicable rules and regulations for the work place.

  • Page 11: Burn Prevention

    SEBU9068-03 Safety Section Burn Prevention Always use leakproof containers when you drain After the engine has stopped, wait for 10 minutes to fluids. Do not pour waste onto the ground, down a allow the fuel pressure to be purged from the high- drain, or into any source of water.

  • Page 12: 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 13 SEBU9068-03 Safety Section Fire Prevention and Explosion Prevention Store fuels and lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials.

  • Page 14: Crushing Prevention And Cutting Prevention

    Do not bend high-pressure lines. Do not strike high- pressure lines. Do not install any lines that are damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for replacement parts. Replace the parts if any of the following conditions are present: •...

  • Page 15: Mounting And Dismounting

    SEBU9068-03 Safety Section Mounting and Dismounting When objects are struck, wear protective glasses in order to avoid injury to the eyes. Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris.
  • Page 16 SEBU9068-03 Safety Section High Pressure Fuel Lines Illustration 11 g03691673 (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...

  • Page 17: Before Starting Engine

    To help prevent an accident that is caused by parts in rotation, work around the parts aid in each cylinder which heats the intake air to improve starting. Some Perkins engines may have a carefully. cold starting system that is controlled by the ECM Do not bypass the automatic shutoff circuits.

  • Page 18: Engine Stopping

    SEBU9068-03 Safety Section Engine Stopping Grounding Practices i02234873 Engine Stopping Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components.

  • Page 19: Engine Electronics

    SEBU9068-03 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 Electronics Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/ or engine damage.
  • Page 20 SEBU9068-03 Safety Section Engine Electronics • 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.

  • Page 21: Product Information Section

    SEBU9068-03 Product Information Section General Information Product Information Section General Information i05837601 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 with Rear Mounted...
  • Page 22 SEBU9068-03 Product Information Section Model View Illustrations (9) Flywheel (11) Spin-on oil filter (13) Oil filler cap (10) Flywheel housing (12) Oil gauge (Dipstick) (14) High-pressure fuel pump Illustration 15 g03693780 Typical example (15) Electronic control module (17) Breather (19) Coolant pump...
  • Page 23 SEBU9068-03 Product Information Section Model View Illustrations Illustration 16 g03693786 Typical example (21) Turbocharger (25) Alternator (29) Starter solenoid (22) Air outlet connection from turbocharger (26) Coolant intake connection (30) Flex pipe (23) Air intake from air cleaner (27) Coolant drain...
  • Page 24 Engine Specifications Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right The Perkins 854F-E34TA industrial engine have the following characteristics sides of the engine are determined from the flywheel end.
  • Page 25 SEBU9068-03 Product Information Section Product Description • Torque rise shaping • Injection timing control • System diagnostics • Aftertreatment Regeneration For more information on electronic engine features, refer to the Operation and Maintenance Manual, “Features and Controls” topic (Operation Section).
  • Page 26 Manual as a guide for required engine maintenance. 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. The aftertreatment system is Diesel Oxidation Catalyst (DOC) and Selective Catalytic Reduction (SCR), with Diesel Exhaust Fluid (DEF) injection.

  • Page 27: Product Identification Information

    Plate Locations and Film Locations (Aftertreatment) 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 Illustration 19 g03733236 Typical example of a non-stressed cylinder block...
  • Page 28 SEBU9068-03 Product Information Section Emissions Certification Film i05847996 Emissions Certification Film The emission label will be installed on the left side of the non-stressed cylinder block. The emission label will be installed on the left side of the engine oil pan...

  • Page 29: Operation Section

    Some removals require lifting the fixtures to obtain correct balance and safety. The lifting eyes should be used to lift only the engine as supplied by Perkins, including engine-mounted aftertreatment equipment. Other Original Equipment Manufacturer (OEM) equipment, including transmissions, should be removed from the engine prior to lifting.
  • Page 30 4. Remove the drive belt from the engine. Product Storage Sealed Coolant System (Engine and Aftertreatment) Ensure that the cooling system is filled with Perkins ELC, or an antifreeze that meets “ASTM D6210” specification. Perkins are not responsible for damage which may...
  • Page 31 SEBU9068-03 Operation Section Engine and Aftertreatment 2. Fill the tank with DEF that meet all the requirement defined in ISO 22241-1. 3. Ensure that all DEF lines and electrical connection are connected prior to prevent crystal from forming. 4. Ensure that the DEF filler cap is correctly installed.

  • Page 32: Features And Controls

    SEBU9068-03 Operation Section Features and Controls Features and Controls Intake manifold pressure – The intake manifold pressure sensor checks the rated pressure in the engine manifold. i05951738 Fuel rail pressure – The fuel rail pressure sensor Alarms and Shutoffs measures the high pressure or low pressure in the fuel rail.
  • Page 33 SEBU9068-03 Operation Section Selective Catalytic Reduction Warning System NOx Sensor – Two NOx sensors monitor the NOx Refer to Troubleshooting for more information. concentration within the exhaust gas. One sensor before the DOC and one after the SCR module. i05858075 SCR Temperature Sensors –...
  • Page 34 • Fast flash (twice a second) Warning Levels Any warning should be investigated immediately, contact your Perkins dealer or your Perkins distributor. The system is equipped with an override option. Once the override option has been used and the fault still exist, the engine will be locked in de-rate at low idle only.
  • Page 35 SEBU9068-03 Operation Section Selective Catalytic Reduction Warning System Table 3 DEF in Tank Level Warning Stop Indicator DEF Low Lev- Emission Mal- DEF in Tank Engine Power Time Comment Action Indicator el Indicator function Level Indicator Full Power Normal None...
  • Page 36 SEBU9068-03 Operation Section Selective Catalytic Reduction Warning System Inducement for Poor DEF Quality Table 4 Inducement for Poor DEF Quality Warning Stop Indicator DEF Quality Emission Mal- Engine Power Time Comment Action Indicator Indicator function Indicator Full Power Normal None...
  • Page 37 SEBU9068-03 Operation Section Selective Catalytic Reduction Warning System SCR System Inducements Table 5 SCR System Inducements Warning Indicator Stop Indicator Emission Malfunc- Engine Power Time Comment Action tion Indicator Full Power Normal Operation None ON Solid or Slow ON Solid...
  • Page 38 Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer Allow at least 2 minutes after the engine has stopped for assistance.
  • Page 39 3. Inspect the cooling system for leaks. If necessary, All lamps will illuminate for 2 seconds in order to consult your Perkins dealer for assistance. check that the lamps are functioning when the keyswitch is turned to the ON position. If any of the Tachometer –...
  • Page 40 SEBU9068-03 Operation Section Monitoring System • Intake pressure • Atmospheric pressure • Fuel temperature Aftertreatment Lamps and Gauges • Emission malfunction lamp • Action indicator lamp • Gauge for Diesel Exhaust Fluid (DEF) • Low warning lamp for DEF i04710837...
  • Page 41 SEBU9068-03 Operation Section Monitoring System (Table 7, contd) Warning Shutdown Lamp State Description of the Indication Engine Status Operator Action Indicator Indicator Flashing Warning Level 2 warning The engine continues to be Stop the engine. operated, but there are active Investigate the code.
  • Page 42 (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 dealer. i04348489 Overspeed • ECM Electronic Control Module •...
  • Page 43 SEBU9068-03 Operation Section Sensors and Electrical Components i05847998 Sensors and Electrical Components Engine Views Illustration 26 g03700023 Typical example (1) High-pressure fuel pump inlet metering (4) 62-pin engine interface connector (8) Water In Fuel (WIF) sensor valve (5) Fuel temperature sensor...
  • Page 44 SEBU9068-03 Operation Section Sensors and Electrical Components Illustration 27 g03700024 Typical example (10) NOx Reduction System (NRS) valve (13) Exhaust gas pressure sensor (16) Secondary speed/timing sensor (11) Intake manifold air pressure and (14) Coolant temperature sensor (camshaft) temperature sensor...
  • Page 45 SEBU9068-03 Operation Section Sensors and Electrical Components On Engine Aftertreatment Illustration 28 g03700027 Typical example (18) Engine out NOx sensor (19) Diesel Exhaust Fluid (DEF) injector (20) DOC inlet temperature sensor...
  • Page 46 SEBU9068-03 Operation Section Sensors and Electrical Components Off Engine Electrical Components Illustration 29 g03700028 Typical example (21) Inlet air temperature sensor (25) Coolant diverter valve (29) Ammonia sensor (22) Breather heater (26) DEF tank header unit (30) Control unit for the ammonia sensor...

  • Page 47: Engine Diagnostics

    ECM. The codes that Perkins electronic engines have the capability to have been logged by the ECM can be identified by perform a self-diagnostics test. When the system the electronic service tool.
  • Page 48 SEBU9068-03 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.
  • Page 49 SEBU9068-03 Operation Section Configuration Parameters (Table 8, 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...
  • Page 50 SEBU9068-03 Operation Section Configuration Parameters (Table 8, 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...

  • Page 51: Engine Starting

    SEBU9068-03 Operation Section Engine Starting Engine Starting i05365825 Cold Weather Starting i05844893 Before Starting Engine Do not use aerosol types of starting aids such as Perform the required daily maintenance and other ether. Such use could result in an explosion and periodic maintenance before the engine is started.
  • Page 52 SEBU9068-03 Operation Section Starting the Engine 5. Repeat step 2 through step 4 if the engine fails to 4. When the warning light for the glow plugs is start. extinguished, turn the keyswitch to the START position in order to engage the electric starting Note: After starting, the engine will be held at low motor and crank the engine.
  • Page 53 SEBU9068-03 Operation Section After Starting Engine 3. Connect one negative end of the jump-start cable to the negative cable terminal of the electrical source. Connect the other negative end of the Improper jump start cable connections can cause an explosion resulting in personal injury.
  • Page 54 SEBU9068-03 Operation Section After Starting Engine • Constant speed engines or constant power engines should be allowed to operate at low idle for 3 minutes before used at operational speed. If the low idle option is not available, then operate the engine at operational speed with no load for 2 minutes.

  • Page 55: Engine Operation

    SEBU9068-03 Operation Section Engine Operation Engine Operation 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. i05949882...
  • Page 56 Fuel Conservation Practices The efficiency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures to attain optimum performance for the life of the engine.

  • Page 57: Cold Weather Operation

    • Keep all batteries fully charged and warm. • Fill the fuel tank at the end of each shift. Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and • Check the air cleaners and the air intake daily.
  • Page 58 Note: Do not restrict the air flow. Restriction of the air in the combustion chamber. This fuel and oil causes flow can damage the fuel system. Perkins soft carbon deposits to form on the valve stems. discourages the use of all air flow restriction devices Generally, the deposits do not cause problems and such as radiator shutters.
  • Page 59 Note: Only use grades of fuel that are recommended The breather heater or other breather thermal by Perkins. Refer to this Operation and Maintenance protection is important and any OEM equipment must Manual, “Fluid Recommendations”. be operational to prevent the risk of breather freezing for operation below −5°...
  • Page 60 SEBU9068-03 Operation Section Fuel Related Components in Cold Weather Another important fuel property which can affect cold For more information about fuel heaters (if equipped), start and operation of diesel engine is Cetane refer to the OEM information. number. Detail and requirements of this property are...

  • Page 61: Engine Stopping

    SEBU9068-03 Operation Section Engine Stopping Engine Stopping Emergency Stop Button i05856294 Stopping the Engine NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and ac- celerated wear of the engine components. Avoid accelerating the engine prior to shutting it down.
  • Page 62 SEBU9068-03 Operation Section After Stopping Engine • Before you check the engine oil, do not operate the engine. Wait for at least 10 minutes after the engine has stopped in order to allow the engine oil to return to the oil pan. Check the crankcase oil level.

  • Page 63: Maintenance Section

    SEBU9068-03 Maintenance Section Refill Capacities Maintenance Section Refill Capacities i05962392 Refill Capacities Lubrication System The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the Original Equipment Manufacture (OEM) specifications for the capacity of the auxiliary oil filter.
  • Page 64 11 . i05859273 NOTICE Fluid Recommendations The footnotes are of the key part Perkins Specifica- tion for Distillate Diesel Fuel Table. Read ALL of the footnotes. • Glossary • ISO International Standards Organization •...
  • Page 65 SEBU9068-03 Maintenance Section Fluid Recommendations Table 11 Perkins Specification for Distillate Diesel Fuel Property UNITS Requirements “ASTM”Test “ISO”Test Aromatics %Volume 35% maximum D1319 “ISO”3837 %Weight 0.01% maximum D482 “ISO”6245 Carbon Residue on 10% %Weight 0.35% maximum D524 “ISO”4262 Bottoms Cetane Number...
  • Page 66 EPA and other appropriate regulatory agencies. NOTICE Operating with fuels that do not meet the Perkins rec- ommendations can cause the following effects: Start- ing difficulty, reduced fuel filter service life, poor combustion, deposits in the fuel injectors, signifi-...
  • Page 67 “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 Perkins recommends kinematic viscosities of 1.4 and 4.5 mm2/sec that is delivered to the fuel injection...
  • Page 68 Your fuel supplier Protection Agency (EPA) and European Certification can make recommendations for additives to use, and fuels. Perkins does not certify engines on any other for the proper level of treatment. fuel. The user of the engine has the responsibility of...
  • Page 69 Consult your supplier of fuel for unknown. assistance in selecting appropriate anti-microbial additive. • Perkins recommend the use of oil analysis in Water accelerates microbial contamination and order to check the quality of the engine oil if growth. When biodiesel is compared to distillate biodiesel fuel is used.
  • Page 70 Licensing If biodiesel or biodiesel blends of fuel are to be used, Perkins require the use of Perkins fuel cleaner. The The Engine Oil Licensing and Certification System by use of the fuel is in order to remove deposits within...
  • Page 71 “EMA Recommended Guideline on Diesel Engine order to select the oil viscosity for engine operation at Oil”. In addition to Perkins definitions, there are other the highest ambient temperature that is anticipated. definitions that will be of assistance in purchasing lubricants.
  • Page 72 This analysis with the finished oil. This failure could produce sludge also allows technicians to verify the performance in the crankcase. Perkins discourages the use of of the oil according to the specification during the aftermarket additives in finished oils.
  • Page 73 Table • Cavitation of the water pump 14 . Table 14 For optimum performance, Perkins recommends a 1:1 mixture of a water/glycol solution. Acceptable Water Property Note: Use a mixture that will provide protection Maximum Limit against the lowest ambient temperature.
  • Page 74 American Society for Testing and • Automotive applications Materials The anti-corrosion package for ELC is different from The following two coolants are used in Perkins diesel the anti-corrosion package for other coolants. ELC is engines: an ethylene glycol base coolant. However, ELC contains organic corrosion inhibitors and antifoam Preferred –...
  • Page 75 Perkins recommends the use of a refractometer for checking the glycol concentration. A hydrometer 6. Fill the cooling system with the Perkins Premixed should not be used. ELC. Operate the engine. Ensure that all coolant valves open then stop the engine.
  • Page 76 The size of the cooling system determines the amount of SCA that is needed. DEF that is used in Perkins engines must meet the ISO specification 22241-1 for quality. The ISO Use the equation that is in Table 20 to determine the...
  • Page 77 30° C (86° F) to 35° C (95° F) 6 months Above 35° C (95° F) test quality before use Perkins recommend that all DEF taken from storage should be checked to ensure that the DEF meets ISO standard 22241-1.

  • Page 78: 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 chassis frame or rail. off the engine. Allow the cooling system pressure cap to cool.
  • Page 79 SEBU9068-03 Maintenance Section Welding on Engines with Electronic Controls 1. Stop the engine. Turn the switched power to the OFF position. 2. Ensure that the fuel supply to the engine is turned off. 3. Disconnect the negative battery cable from the battery.
  • Page 80 Operation and Maintenance Manual, “Fluid severe service operation. Consult your Perkins Recommendations”. distributor for the unique maintenance that is necessary for the engine.

  • Page 81: Maintenance Interval Schedule

    SEBU9068-03 Maintenance Section Maintenance Interval Schedule “ Engine Air Cleaner Element (Dual Element) - i08315603 Inspect/Clean/Replace“ ..... . 95 Maintenance Interval Schedule “...
  • Page 82 SEBU9068-03 Maintenance Section Maintenance Interval Schedule “ Diesel Exhaust Fluid Filter - Clean/Replace“ ..93 Every 3000 Service Hours or 2 Years “ Coolant (DEAC) - Change“ ....86 Every 4000 Service Hours “...
  • Page 83 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 84: Battery - Replace

    SEBU9068-03 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 36 .

  • Page 85: Battery Or Battery Cable - Disconnect

    SEBU9068-03 Maintenance Section Battery Electrolyte Level - Check Note: Always recycle a battery. Never discard a Thoroughly rinse the battery case with clean battery. Dispose of used batteries to an appropriate water. recycling facility. i07819485 6. Remove the used battery.
  • Page 86 SEBU9068-03 Maintenance Section Coolant (DEAC) - Change 1. Stop the engine and allow the engine to cool. i05859216 Loosen the cooling system filler cap slowly in Coolant (DEAC) - Change order to relieve any pressure. Remove the cooling system filler cap.
  • Page 87 Decrease the engine speed to low idle. Stop the engine. For information regarding the disposal and the 4. Maintain the coolant level at the maximum mark recycling of used coolant, consult your Perkins that is correct for your application. distributor. Flush 1.
  • Page 88 SEBU9068-03 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.
  • Page 89 The full distil- lation procedure is the only method acceptable by Perkins to reclaim the coolant. For information regarding the disposal and the recycling of used coolant, consult your Perkins distributor. Flush 1. Flush the cooling system with clean water in order to remove any debris.
  • Page 90 Remove the filler cap. i05197396 Coolant Extender (ELC) - Add 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 distributor.

  • Page 91: Def Filler Screen - Clean

    Engine with Radiator Installed by 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: Diesel Exhaust Fluid - Fill

    SEBU9068-03 Maintenance Section DEF Manifold Filters - Replace 4. If the filter screen cannot be cleaned or the filter i06216651 screen is damaged, then the filter screen must be Diesel Exhaust Fluid - Fill replaced. 5. Install filter screen (3) into DEF tank neck adapter (4).
  • Page 93 SEBU9068-03 Maintenance Section Diesel Exhaust Fluid Filter - Clean/Replace 2. Ensure that the DEF cap (1) and the surrounding i05940598 area is clean and free from dirt. Ensure that all Diesel Exhaust Fluid Filter - equipment use in filling the tank is clean and free from dirt.

  • Page 94: Diesel Exhaust Fluid Tank - Flush

    SEBU9068-03 Maintenance Section Diesel Exhaust Fluid Tank - Flush 3. Replace the DEF filter. Refer to Operation and i07417986 Maintenance Manual, “Diesel Exhaust Fluid Filter - Diesel Exhaust Fluid Tank - Clean/Replace” for the correct procedure. Flush Note: This filter is to be used for the flushing process only.

  • Page 95: Engine - Clean

    Note: The air filter system may not have been • Easy detection of fluid leaks provided by Perkins. The procedure that follows is for a typical air filter system. Refer to the OEM • Maximum heat transfer characteristics information for the correct procedure.

  • Page 96: Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

    SEBU9068-03 Maintenance Section Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace Dual Element Air Cleaners 7. Reset the air cleaner service indicator. The dual element air cleaner contains a primary air Cleaning the Primary Air Cleaner cleaner element and a secondary air cleaner Elements element.

  • Page 97: Engine Air Cleaner Element (Single Element) - Inspect/Replace

    SEBU9068-03 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace Pressurized Air Note: Refer to “Inspecting the Primary Air Cleaner Elements”. Inspecting the Primary Air Cleaner Elements Personal injury can result from air pressure. Personal injury can result without following prop- er procedure.
  • Page 98 SEBU9068-03 Maintenance Section Engine Air Cleaner Service Indicator - Inspect Some engines are equipped with a differential gauge NOTICE for inlet air pressure. The differential gauge for inlet Never run the engine without an air cleaner element air pressure displays the difference in the pressure installed.
  • Page 99 SEBU9068-03 Maintenance Section Engine Air Precleaner - Check/Clean Engine Breather The service indicator may need to be replaced frequently in environments that are severely dusty. NOTICE i05967804 Ensure that the engine is stopped before any servic- ing or repair is performed.
  • Page 100 Any engine mount that shows deterioration should be replaced. Refer to the OEM information for the recommended torques. When the engine mounts are supplied by Perkins the maintenance procedure will be supplied in the Disassembly and Assembly manual for your engine.

  • Page 101: Engine Oil Sample - Obtain

    Hot oil and hot components can cause personal valve is positioned on the cylinder block. injury. Do not allow hot oil or hot components to Perkins recommends using a sampling valve in order contact the skin. to obtain oil samples. The quality and the consistency of the samples are better when a sampling valve is used.
  • Page 102 Failure to follow this recommended procedure will cations. Use of an oil filter that is not recommended by Perkins could result in severe damage to the en- cause the waste particles to be recirculated through gine bearings, crankshaft, as a result of the larger the engine lubrication system with the new oil.
  • Page 103 SEBU9068-03 Maintenance Section Fan Clearance - Check 4. Install the engine oil filter, spin on the oil filter until 3. Stop the engine and allow the oil to drain back to the O ring seal contacts the oil filter base. Then, the oil pan for a minimum of 10 minutes.

  • Page 104: Fuel System - Prime

    SEBU9068-03 Maintenance Section 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 Do not crank the engine continuously for more than the fan blade.
  • Page 105 SEBU9068-03 Maintenance Section 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 106 SEBU9068-03 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 6. Tighten the vent screw (1) securely . Remove the 8. Rotate the filter element counterclockwise and wiring harness from connection (4). remove the filter element (5). Clean the filter bowl.

  • Page 107: Fuel System Primary Filter/Water Separator

    SEBU9068-03 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”.
  • Page 108 SEBU9068-03 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.

  • Page 109: Drain

    SEBU9068-03 Maintenance Section Fuel Tank Water and Sediment - Drain 2. Lubricate the O ring seal (6) with clean engine oil. Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the Do NOT fill the filter bowl (2) with fuel before the drain valve.
  • Page 110 Radiator - Clean Replace the Hoses and the Clamps Refer to the OEM information for further information The radiator is not usually supplied by Perkins. The on removing and replacing fuel hoses (if equipped). following text describes a typical cleaning procedure for the radiator.
  • Page 111 Adjusting Manual, “Electric Starting System - 1. Ensure that the turbocharger is clean and free from Test” for more information on the checking procedure and for specifications consult your Perkins dealer or dirt before removing components for inspection. your Perkins distributor for assistance.
  • Page 112 Refer to Disassembly and Assembly , “Water Pump - securely. For more information, refer to Systems Remove and Install”. For more information, consult your Perkins dealer or your Perkins distributor . Operation, Testing, and Adjusting, “Turbocharger - Inspect”. • Inspect the lubrication system for leaks at the front...
  • Page 113 SEBU9068-03 Maintenance Section Water Pump - Inspect Belts for multiple groove pulleys must be replaced as • Check the condition of the gauges. Replace any matched sets. If only one belt is replaced, the belt will gauges that are cracked. Replace any gauge that carry more load than the belts that are not replaced.
  • Page 114 SEBU9068-03 Maintenance Section Water Pump - Inspect Note: If engine coolant enters the engine lubricating system, the lubricating oil and the engine oil filter must be replaced. Draining will remove any contaminate and will prevent any irregular oil samples. In order to install a new water pump, refer to the Disassembly and Assembly Manual, “Water Pump -...

  • Page 115: Warranty Section

    (“emission-related components”), are: For a detailed explanation of the Emission Control Warranty, contact your authorized Perkins dealer or a. Designed, built, and equipped so as to conform, your authorized Perkins distributor. at the time of sale, with applicable emission...

  • Page 116: Reference Information Section

    Maintenance records are a key element of a maintenance program that is correctly managed. Accurate maintenance records can help your Perkins dealer to fine-tune the recommended maintenance intervals in order to meet the specific operating situation. This should result in a lower engine operating cost.
  • Page 117 SEBU9068-03 Reference Information Section Maintenance Log i05204675 Maintenance Log Table 23 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel...
  • Page 118 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 119: Index

    SEBU9068-03 Index Section Index Coolant Level - Check ........90 Engine with Radiator Installed by OEM..91 After Starting Engine ........53 Engine with Radiator Installed by the Engine After Stopping Engine ........61 Manufacturer..........90 Aftercooler Core - Clean/Test (Air-To-Air Crushing Prevention and Cutting Prevention..
  • Page 120 SEBU9068-03 Index Section Fill the Oil Pan..........103 Fuel System Primary Filter (Water Replace the Oil Filter ......... 102 Separator) Element - Replace..... 105 Engine Oil Level - Check....... 100 Install the Element ........106 Engine Oil Sample - Obtain......101 Remove the Element .........
  • Page 121 Starting Motor - Inspect ........111 (Aftertreatment) ..........27 Starting the Engine.......... 52 Product Description ......... 24 Starting the Engine ........52 Aftermarket Products and Perkins Starting with Jump Start Cables (Do Not Engines ............26 Use This Procedure in Hazardous Aftertreatment System......... 26 Locations that have Explosive Electronic Engine Features ......
  • Page 122 SEBU9068-03 Index Section Walk-Around Inspection .........112 Aftertreatment System........113 High Pressure Fuel Lines ......113 Inspect the Engine for Leaks and for Loose Connections ..........112 Warranty Information........115 Warranty Section ..........115 Water Pump - Inspect........113 Welding on Engines with Electronic Controls ............78...
  • Page 123 Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:...
  • Page 124 SEBU9068 ©2020 Perkins Engines Company Limited All Rights Reserved December 2020...

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