Perkins 800D Series Operation And Maintenance Manual
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Perkins 800D Series Operation And Maintenance Manual

Perkins 800D Series Operation And Maintenance Manual

Industrial engines
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SEBU8324-02 (en-us)
January 2021
Operation and
Maintenance
Manual
800D Series Industrial Engines
UK (Engine)
UL (Engine)

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Summary of Contents for Perkins 800D Series

  • Page 1 SEBU8324-02 (en-us) January 2021 Operation and Maintenance Manual 800D Series Industrial Engines UK (Engine) UL (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

    SEBU8324-02 Table of Contents Table of Contents Maintenance Interval Schedule....... 51 Warranty Section Foreword ............4 Warranty Information........73 Safety Section Index Section Safety Messages..........6 Index..............74 General Hazard Information......8 Burn Prevention..........12 Fire Prevention and Explosion Prevention..12 Crushing Prevention and Cutting 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 damaged warning signs or missing warning signs. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Any Perkins dealer or any Perkins distributor can provide new warning signs.
  • Page 7 SEBU8324-02 Safety Section Safety Messages Illustration 1 g01353473 Typical example (1) Universal Warning (2) Warning label for the Starting Aid Universal Warning (1) The universal warning label (1) is located on the top of the valve mechanism cover.

  • Page 8: General Hazard Information

    SEBU8324-02 Safety Section General Hazard Information Illustration 2 g01273386 Illustration 3 g01273387 Do not operate or work on this engine unless you Do not use aerosol types of starting aids such as have read and understand the instructions and ether. Such use could result in an explosion and warnings in the Operation and Maintenance Man- personal injury.
  • Page 9 SEBU8324-02 Safety Section General Hazard Information Start the engine from the operators station (cab). Never short across the starting motor terminals or the batteries. This action could bypass the engine neutral start system and/or the electrical system could be damaged. Engine exhaust contains products of combustion which may be harmful to your health.
  • Page 10 SEBU8324-02 Safety Section General Hazard Information Obey all local regulations for the disposal of liquids. Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel The removal of sulfur and other compounds in ultra- low sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge.
  • Page 11 Inhaling this dust can be hazardous with applicable regulations and requirements where to your health. The components that may contain originally sold. Perkins recommends the use of only asbestos fibers are brake pads, brake bands, lining genuine Perkins replacement parts.

  • Page 12: Burn Prevention

    SEBU8324-02 Safety Section Burn Prevention Dispose of Waste Properly Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth. Oils Hot oil and hot lubricating components can cause personal injury.
  • Page 13 SEBU8324-02 Safety Section Fire Prevention and Explosion Prevention 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 14: Crushing Prevention And Cutting Prevention

    Repair any lines that are loose or damaged. Leaks Inspect the steps, the handholds, and the work area can cause fires. Consult your Perkins dealer or your before mounting the engine. Keep these items clean Perkins distributor for repair or for replacement parts.

  • Page 15: Before Starting Engine

    SEBU8324-02 Safety Section Before Starting Engine If a warning tag is attached to the engine start switch i08258438 or to the controls, DO NOT start the engine or move Before Starting Engine the controls. Consult with the person that attached the warning tag before the engine is started.

  • Page 16: Electrical System

    SEBU8324-02 Safety Section Electrical System On the initial start-up of a new engine or an engine that has been serviced, make provisions to stop the engine if an overspeed condition occurs. Engine stopping may be accomplished by shutting off the fuel supply and/or the air supply to the engine.

  • Page 17: Product Information Section

    SEBU8324-02 Product Information Section Model Views Product Information Section Model Views i02697676 Model View Illustrations Illustration 12 g01264543 Left side view of a naturally aspirated engine This view is shown without one of the fuel injectors for clarity. (1) Fan (4) Oil filler cap (7) Oil level gauge (2) Fuel injector...
  • Page 18 SEBU8324-02 Product Information Section Model View Illustrations (10) Relief valve (12) Oil pressure switch (14) Oil Filler (11) Oil drain plug (13) Fuel injection pump (15) Water pump Illustration 13 g01264517 (16) Oil filler cap (19) Alternator (22) Starting motor (17) Lifting eye (20) V-Belt (23) Exhaust manifold...
  • Page 19 SEBU8324-02 Product Information Section Model View Illustrations Illustration 14 g01353575 Left side view of turbocharged engine (1) Glow plug (6) Oil level gauge (11) Oil filler (2) Inlet manifold (7) Fuel injection pump (12) V-belt (3) Fuel injector (8) Oil filter (13) Oil cooler (4) Crankcase breather (9) Relief valve...
  • Page 20 SEBU8324-02 Product Information Section Engine Description Illustration 15 g01353864 Right side view of turbocharged engine (15) Turbocharger (19) Starting motor (23) Exhaust manifold (16) Front lifting eye (20) Oil pan (24) Rear lifting eye (17) Coolant switch (21) Flywheel housing (25) Top oil filler (18) Alternator (22) Flywheel...
  • Page 21 SEBU8324-02 Product Information Section Engine Description Engine efficiency, efficiency of emission controls, and (Table 1, contd) engine performance depend on adherence to proper Displacement 3.33 L (203 in operation and maintenance recommendations. Engine performance and efficiency also depend on Firing Order 1-3-4-2 the use of recommended fuels, lubrication oils, and coolants.

  • Page 22: Product Identification Information

    Engine Low Idle rpm Illustration 16 g01372283 Location of serial number plate Engine Full Load rpm Primary Fuel Filter Perkins engines are identified by an engine serial number. Water Separator Element An example of an engine number is Secondary Fuel Filter Element UL*****J000001L.
  • Page 23 SEBU8324-02 Product Information Section Emissions Certification Film Alternator Belt i02742745 Emissions Certification Film Illustration 18 g01372645 Typical example • EPA Environmental Protection Agency • CARB California Air Resources Board • EEC European Economic Community The emissions label (1) is located on the top of the valve mechanism cover.
  • Page 24 SEBU8324-02 Product Information Section Emissions Certification Film Illustration 19 g01381011 Typical example...

  • Page 25: Operation Section

    Product Lifting walls. Rust on the cylinder walls will cause increased engine wear and a reduction in engine service life. Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.
  • Page 26 SEBU8324-02 Operation Section Product Storage Renew the canister(s) of the lubricating oil filter. Fill the oil pan to the Full Mark on the engine oil level gauge with new, clean lubricating oil. Add 1762811 POWERPART Lay-Up 2 to the oil in order to protect the engine against corrosion.

  • Page 27: Gauges And Indicators

    Ammeter – This gauge indicates the Determine and correct the cause of any significant amount of charge or discharge in the change in the readings. Consult your Perkins dealer battery charging circuit. Operation of or your Perkins distributor for assistance.

  • Page 28: Features And Controls

    • Types and locations of shutoff Refer to the Service Manual for more information on • Conditions which cause each shutoff to function testing procedures or consult your Perkins dealer. • The resetting procedure that is required to restart i02539718...

  • Page 29: Engine Starting

    SEBU8324-02 Operation Section Engine Starting Engine Starting • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or i02194223 to the controls. Before Starting Engine •...
  • Page 30 SEBU8324-02 Operation Section Starting with Jump Start Cables NOTICE NOTICE Do not crank the engine for more than 10 seconds. Using a battery source with the same voltage as the Allow the starter motor to cool for 30 seconds before electric starting motor.
  • Page 31 SEBU8324-02 Operation Section After Starting Engine • Check for any fluid or for any air leaks at idle rpm and at one-half full rpm (no load on the engine) before operating the engine under load. This is not possible in some applications. •...

  • Page 32: Engine Operation

    SEBU8324-02 Operation Section Engine Operation Engine Operation 2. Check all of the gauges during the warm-up period. 3. Perform a walk-around inspection. Check the i06015869 engine for fluid leaks and air leaks, only then apply Engine Operation the load. i01646335 Proper operation and maintenance are key factors in Engaging the Driven obtaining the maximum life and economy of the...
  • Page 33 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 in order to attain optimum performance for the life of the engine.

  • Page 34: Engine Stopping

    SEBU8324-02 Operation Section Engine Stopping Engine Stopping i03756631 After Stopping Engine i06832774 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 •...

  • Page 35: Cold Weather Operation

    Cold Weather Operation • Install the correct specification of engine lubricant before the beginning of cold weather. Perkins Diesel Engines can operate effectively in • Check all rubber parts (hoses, fan drive belts.) cold weather. During cold weather, the starting and weekly.
  • Page 36 An electric block heater can be activated once the • Pushrods may become bent. engine is stopped. An effective block heater is typically a 1250/1500 W unit. Consult your Perkins • Other damage to valve train components can dealer or your Perkins distributor for more result.
  • Page 37 As the jacket water Note: Group 3 fuels reduce the life of the engine. The coolant temperature rises above the minimum use of Group 3 fuels is not covered by the Perkins operating temperature the water temperature warranty.
  • Page 38 SEBU8324-02 Operation Section Fuel Related Components in Cold Weather Be aware of these values when diesel fuel is The micron rating and the location of a primary fuel purchased. Consider the average ambient air filter is important in cold weather operation. The temperature for the engine's application.

  • Page 39: Maintenance Section

    The external cooling system includes a radiator or an expan- sion tank with the following components: The heat exchanger, the aftercooler, and the piping Refer to the Perkins specifica- Refill Capacities tions and/or the OEM specifications. Enter the value for the ex- ternal cooling system capacity in this row.
  • Page 40 The classifications CD-2 and American Petroleum Institute CF- and improved resistance to plugging of the oil filter. 2 are for two-cycle diesel engines. Perkins does not sell en- These oils will also provide superior piston deposit gines that utilize CD-2 and API CF-2 oils.
  • Page 41 API CH-4 oils are recommended for wear metal analysis. conditions that demand a premium oil. Your Perkins dealer or your Perkins distributor has specific Excessive piston deposits can be produced by an oil guidelines for optimizing oil change intervals.
  • Page 42 Perkins does not recommend the automatic Perkins does not recommend the use of aftermarket extending of the oil change intervals for any type of additives in oil. It is not necessary to use aftermarket oil.
  • Page 43 To get the correct power and performance from the engine, use a fuel of the correct quality. The Note: Only use Arctic fuels when the temperature is recommended fuel specification for Perkins engines below 0 °C (32 °F). Do not use Arctic fuels when the is shown below: ambient temperature is above 0 °C (32 °F).
  • Page 44 These fuels need additives to achieve lubricity of 650 Table 9 micrometers wear scar and the reliability of the fuel Perkins Specifications for Distillate Diesel Fuel pump and fuel injectors will be reduced. The fuel injection pump is not covered by a warranty, even...
  • Page 45 The fuels that are listed in this Table may not meet the require- Gum and Resins 10 mg per 100 mL “D381” ments that are specified in the “Perkins Specifications for Distil- maximum late Diesel Fuel” Table. Consult the supplier for the recommended additives in order to maintain the correct fuel 0.38 mm...
  • Page 46 • Freezing use water with the properties that are listed in Table 11 . • Cavitation of the water pump Table 11 For optimum performance, Perkins recommends a Acceptable Water 1:1 mixture of a water/glycol solution. Property Maximum Limit Note: Use a mixture that will provide protection...
  • Page 47 “ASTM D4985” Coolant Recommendations Perkins POWERPART SCA 3000 Service Hours or Two Years The following two coolants are used in Perkins diesel Commercial SCA and Water 3000 Service Hours or Two Years engines: Preferred – Perkins Extended Life Coolant (ELC)
  • Page 48 Maintenance Section Fluid Recommendations Changing to Perkins ELC Containers of several sizes are available. Consult your Perkins dealer or your Perkins distributor for the part numbers. To change from heavy-duty coolant or antifreeze to the Perkins ELC, perform the following steps:...
  • Page 49 Mixing Extended Life Coolant (ELC) with other prod- Perkins Liquid SCA ucts reduces the effectiveness of the ELC and short- ens the ELC service life. Use only Perkins Products Quantity Part Number for pre mixed or concentrate coolants. Failure to fol-...
  • Page 50 × 0.014 0.2 L (7 oz) Cleaning the System of Heavy-Duty coolant or antifreeze Perkins cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion. Perkins cooling system cleaners dissolve mineral scale, corrosion products, light oil contamination and sludge.

  • Page 51: Maintenance Interval Schedule

    SEBU8324-02 Maintenance Section Maintenance Interval Schedule “ Engine Oil and Filter - Change“....62 i08341780 Maintenance Interval Schedule “ Fuel System Filter - Replace“ ....65 “...
  • Page 52 A correctly Alternator - Inspect adjusted belt will deflect 10 mm (0.39 inch). Adjustment Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and correct battery charging. Check the ammeter (if equipped) during engine operation in order to ensure correct battery performance and/or correct performance of the electrical system.
  • Page 53 SEBU8324-02 Maintenance Section Battery - Replace When new belts are installed, check the belt tension 8. Connect the cable from the NEGATIVE “-” terminal again after 20 hours of engine operation. on the starter motor to the NEGATIVE “-” battery terminal.
  • Page 54 SEBU8324-02 Maintenance Section Battery or Battery Cable - Disconnect i07819485 i02554793 Battery or Battery Cable - Cooling System Coolant Disconnect (Commercial Heavy-Duty - Change (Commercial Heavy Duty) The battery cables or the batteries should not be removed with the battery cover in place. The bat- NOTICE tery cover should be removed before any servic- Care must be taken to ensure that fluids are con-...
  • Page 55 Stop the engine. For information regarding the disposal and the 4. Check the coolant level. Maintain the coolant level recycling of used coolant, consult your Perkins dealer within 13 mm (0.5 inch) below the bottom of the or your Perkins distributor.
  • Page 56 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 57 SEBU8324-02 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 seri- Add the SCA, If Necessary ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool.
  • Page 58 Note: The air filter system may not have been conductivity. provided by Perkins. The procedure that follows is for a typical air filter system. Refer to the OEM Make sure that the electrical system is OFF. Lock information for the correct procedure.
  • Page 59 SEBU8324-02 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace Replace the dirty air cleaner elements with clean air 5. Remove the tapefrom the air inlet. Install the cleaner elements. Before installation, the air cleaner secondary air cleaner element. Install a primary air elements should be thoroughly checked for tears cleaner element that is new or cleaned.
  • Page 60 SEBU8324-02 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 61 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 62 Engine Oil and Filter - Change NOTICE Perkins oil filters are built to Perkins specifications. Use of an oil filter not recommended by Perkins could result in severe engine damage to the engine bear- ings, crankshaft, etc., as a result of the larger waste...
  • Page 63 Due to normal wear and friction, it is not uncommon to find small amounts of debris in the oil filter. Consult your Perkins distributor in order to NOTICE To prevent crankshaft bearing damage, crank the en- arrange for a further analysis if an excessive gine with the fuel OFF.
  • Page 64 NOTICE Only qualified service personnel should perform this maintenance. Refer to the Service Manual or your Perkins dealer or your Perkins distributor for the com- plete valve lash adjustment procedure. Operation of Perkins engines with improper valve ad- justments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.
  • Page 65 SEBU8324-02 Maintenance Section Fuel System Filter - Replace i02702079 Fuel System Filter - Replace Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.
  • Page 66 SEBU8324-02 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 2. Clean the outside of the fuel filter assembly. Open drain valve (6) and allow the fluid to drain into a suitable container. 3. Remove sediment bowl (5). NOTICE Do not use a tool in order to remove the fuel filter. At- tempting to remove the fuel filter with a filter wrench or a filter strap could damage the locking ring.
  • Page 67 SEBU8324-02 Maintenance Section Fuel Tank Water and Sediment - Drain Some fuel tanks use supply pipes that allow water i02335436 and sediment to settle below the end of the fuel Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank.
  • Page 68 Refer to the OEM information for further information on removing and replacing fuel hoses (if equipped). The radiator is not usually supplied by Perkins. The following text describes a typical cleaning procedure The coolant system and the hoses for the coolant for the radiator.
  • Page 69 Refer to the standards for the engine or consult your the fan's air flow. Hold the nozzle approximately Perkins dealer or your Perkins distributor in order to 6 mm (0.25 inch) away from the radiator fins. Slowly determine if the engine is operating within the defined move the air nozzle in a direction that is parallel with parameters.
  • Page 70 Refer to the Systems Operation, Testing For options regarding the removal, installation, repair and Adjusting Manual, “Electric Starting System - and replacement, consult your Perkins dealer or your Test” for more information on the checking procedure Perkins distributor. Refer to the Disassembly and and for specifications consult your Perkins dealer or Assembly Manual, “Turbocharger - Remove and...
  • Page 71 Fasten the air intake pipe and “Water Pump - Remove and Install” for more the exhaust outlet pipe to the turbocharger information or consult your Perkins dealer or your housing. Perkins distributor. • Inspect the lubrication system for leaks at the front...
  • Page 72 SEBU8324-02 Maintenance Section Water Pump - Inspect Note: The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and parts contract. Visually inspect the water pump for leaks.

  • Page 73: Warranty Section

    This engine may be covered by an Emissions Warranty. Consult your authorized Perkins dealer or distributor to determine if your engine is emissions certified and if your engine is subject to an Emissions...

  • Page 74: Index

    SEBU8324-02 Index Section Index After Starting Engine ........30 Electrical System..........16 After Stopping Engine ........34 Grounding Practices ........16 Alternator - Inspect .......... 52 Emergency Stopping........34 Alternator and Fan Belts - Inspect/Adjust/ Emissions Certification Film ......23 Replace ............
  • Page 75 SEBU8324-02 Index Section Engine Oil ............ 40 Fuel Specifications ........43 Maintenance Interval Schedule....... 51 General Lubricant Information..... 39 Daily ............. 51 Foreword ............4 Every 1000 Service Hours......51 California Proposition 65 Warning ....4 Every 2 Years..........51 Literature Information ........
  • Page 76 SEBU8324-02 Index Section Stopping the Engine ........34 Table of Contents ..........3 Turbocharger - Inspect (If Equipped) ....70 Cleaning and Inspecting ......70 Removal and Installation ......70 Walk-Around Inspection ........71 Inspect the Engine for Leaks and for Loose Connections ..........
  • Page 77 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 78 SEBU8324 ©2021 Perkins Engines Company Limited All Rights Reserved January 2021...

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