Perkins 5008AC-E30TA Operation And Maintenance Manual
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Perkins 5008AC-E30TA Operation And Maintenance Manual

Perkins 5008AC-E30TA Operation And Maintenance Manual

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M0122761-03 (en-us)
June 2024
Operation and
Maintenance
Manual
5006A-E23TA, 5008A-E30TA, 5008C-
E30TA, and 5008AC-E30TA Industrial
Engines

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  • Page 1 M0122761-03 (en-us) June 2024 Operation and Maintenance Manual 5006A-E23TA, 5008A-E30TA, 5008C- E30TA, and 5008AC-E30TA Industrial Engines...
  • 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

    M0122761-03 Table of Contents Table of Contents Maintenance Section Refill Capacities..........55 Foreword ............4 Maintenance Recommendations ....61 Safety Section Maintenance Interval Schedule (50Hz Engines Safety Messages..........6 in Standby Applications)........ 62 Additional Messages ........12 Maintenance Interval Schedule (Engines in Prime Power Applications) ......

  • 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 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. Illustration 1...
  • Page 7 M0122761-03 Safety Section Safety Messages Illustration 2 g06645122 Typical example of an earlier engine (1) Universal warning label locations (7) Rotating shaft hand crush hazard label (5) Hot surface label location location...
  • Page 8 M0122761-03 Safety Section Safety Messages Illustration 3 g07583017 Typical example of a later engine (1) Universal warning label locations (3) Electrocution danger label location (5) Hot surface label location (2) Do not step label location (4) Hot fluid under pressure label locations (6) Ether warning label location...
  • Page 9 M0122761-03 Safety Section Safety Messages Illustration 4 g07583027 Typical example of a later engine (1) Universal warning label locations (5) Hot surface label location 1 Universal Warning Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals.
  • Page 10 M0122761-03 Safety Section Safety Messages 4 Hot Fluid Under Pressure Illustration 6 g01393287 Do not use this surface as a step or platform. This Illustration 8 g01371640 surface may not support additional weight or may be slippery. Serious injury or death could occur from a fall.
  • Page 11 Ether warning label (6) is on the support bracket for positions. One label is on the end cover of the oil the air cleaners. cooler. Perkins recommends that the other hot fluid under pressure label is installed on the radiator, next 7 Rotating Shaft Hand Crush to the coolant filler cap.

  • Page 12: Additional Messages

    M0122761-03 Safety Section Additional Messages The rotating shaft hand crush hazard label (7) is on the cover of the crankshaft vibration damper. i09763589 Additional Messages Illustration 14 g00955999 Typical example Label (2) will be installed on coolant pipe next to the oil filler.
  • Page 13 • Perkins recommend that you do not stand next to • For initial start-up of a new engine or for starting an exposed running engine unless it is necessary...
  • Page 14 M0122761-03 Safety Section General Hazard Information • Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. • Ensure that all protective guards and all covers are secured in place on the engine. •...
  • Page 15 (ULSD fuel) poses a greater good hygiene, and adhering to safe work practices static ignition hazard than earlier diesel formula- when handling the equipment or parts. Perkins also tions with a higher sulfur contents. Avoid death recommends the following: or serious injury from fire or explosion.

  • Page 16: Burn Prevention

    M0122761-03 Safety Section Burn Prevention • Use exhaust ventilation on permanent machining Check that the coolant level after the engine has stopped and the engine has been allowed to cool. jobs. Ensure that the filler cap is cool before removing the •...

  • Page 17: Fire Prevention And Explosion Prevention

    Prolonged exposure to diesel may If the application involves the presence of cause various skin conditions. Appropriate personal combustible gases, consult your Perkins dealer and/ protective equipment should be used. Refer to or your Perkins distributor for additional information supplier Material safety Data sheets for detailed about suitable protection devices.
  • Page 18 M0122761-03 Safety Section Fire Prevention and Explosion Prevention Oil filters and fuel filters must be installed correctly. The filter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for more information. Illustration 22 g00704135 Gases from a battery can explode.

  • Page 19: Crushing Prevention And Cutting Prevention

    Do not install any lines that are damaged. i10005610 Leaks can cause fires. Consult your Perkins distributor for replacement parts. Before Starting Engine Replace the parts if any of the following conditions are present: •...

  • Page 20: Engine Starting

    M0122761-03 Safety Section Engine Starting • Ensure 24V is supplied to the dosing cabinet for at i06545901 least 120 seconds after engine shutdown (engines Engine Starting equipped with SCR systems only). Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping.

  • Page 21: Engine Electronics

    Note: Many of the engine control systems and or a direct engine ground to the frame. display modules that are available for Perkins All grounds should be tight and free of corrosion. The Engines will work in unison with the Engine engine alternator must be grounded to the negative Monitoring System.

  • Page 22: Product Information Section

    M0122761-03 Product Information Section Model Views Product Information Section Model Views i09766575 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 Views Illustration 23 g06617703 Typical example an earlier engine (1) Twin air cleaners...
  • Page 23 M0122761-03 Product Information Section Model View Illustrations Illustration 24 g06643111 Typical example an earlier engine (14) Thermostat housing (17) Oil drain plug (20) Front lifting eye (15) Breather (18) Crankshaft damper (16) Turbochargers (19) Fan belts...
  • Page 24 M0122761-03 Product Information Section Model View Illustrations Radiator View Illustration 25 g06618854 Typical example of an earlier Radiator (1) Radiator cap (3) Coolant drain (5) Air to air charge cooler (2) Radiator (4) Fuel cooler (6) Coolant vent...
  • Page 25 M0122761-03 Product Information Section Model View Illustrations Illustration 26 g07584153 Typical example a later engine (1) Twin air cleaners (6) Radiator lifting eye (1 of 2) (11) Twin secondary fuel filters (2) Oil cooler (7) Coolant pump (12) Oil filters (3) Alternator (8) Module for twin primary fuel filters (13) Starting motor...
  • Page 26 M0122761-03 Product Information Section Model View Illustrations Illustration 27 g07584823 Typical example a later engine with radiator removed (16) Thermostat housing (19) Oil drain plug (22) Front lifting eye (17) Breather (20) Crankshaft damper (18) Turbochargers (21) Fan belts...
  • Page 27 M0122761-03 Product Information Section Model View Illustrations Illustration 28 g07585157 Typical example of a later engine (23) Radiator (25) Coolant vent (27) Fuel cooler (24) Radiator cap (26) Radiator lifting eye (2 of 2) (28) Air to air charge cooler...
  • Page 28 The number 1 cylinder is the front cylinder. The Perkins 5006A-E23TA, 5008A-E30TA, 5008C- E30TA, and 5008AC-E30TA Industrial Engines have the following characteristics: • Four stroke cycle • Mechanically actuated, electronically controlled fuel injection system •...
  • Page 29 (B) Exhaust valves Table 1 Table 2 Engine Specifications Engine Specifications Engine Engine 5008A-E30TA, 5008C-E30TA, 5006A-E23TA and 5008AC-E30TA Arrangement and Cylinders In-Line 6 cylinder Arrangement and cylinders In-line 8 cylinder Bore 160 mm (6.30 inch) Bore 160 mm (6.30 inch) Stroke 190 mm (7.48 inch)
  • Page 30 Aftermarket Products and Perkins Engines Perkins does not warrant the quality or performance of non-Perkins fluids and filters. When auxiliary devices, accessories, or consumables (filters, additives, catalysts) which are made by other manufacturers are used on Perkins products, the Perkins warranty is not affected simply because of such use.

  • Page 31: Product Identification Information

    (2) Engine serial number plate and engine ratings labels location Illustration 36 g07789135 Typical example of a type 2 serial number with ratings information label Your Perkins distributor needs all the number from Illustration 33 g07789122 these labels when service information is required. Typical example of a later engine...
  • Page 32 M0122761-03 Product Information Section Plate Locations and Film Locations Emission Label The emission label (1) is installed on the inlet manifold on earlier engines and on the oil cooler on later engines. Illustration 37 g06646849 Typical example of type 1 Emissions label Illustration 38 g07789140 Typical example of type 2 Emissions label...

  • Page 33: Operation Section

    M0122761-03 Operation Section Lifting and Storage Operation Section Lifting and Storage i09768521 Product Lifting Engine Only - Earlier Engines NOTICE Always inspect lifting eyebolts and all other lifting equipment for damage before performing any lifting. Never bend the eyebolts and the brackets. Never perform product lifting if components are damaged.
  • Page 34 M0122761-03 Operation Section Product Lifting Radiator Only Illustration 40 g06649667 Typical example of a 5008 radiator (1) Radiator lifting eyes Later engines On later engines, the radiator and the engine are to be disassembled before lifting and to be lifted separately.
  • Page 35 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 Perkins are not responsible for damage which may −36°...
  • Page 36 0.15 mL per L (.02 oz per 1 gal US) of commercial biocide such as Biobor JF to the fuel. Refer to 1. Clean the engine of any dirt, rust, grease, and oil. “Perkins Diesel Engines Fluids Inspect the exterior. Paint areas that contain paint Recommendations”M0113102 for more damage with a good quality paint.
  • Page 37 8. If an engine is stored for more than 1 year, Perkins recommends prelubrication of the engine to avoid dry starting. Use a suitable pump to put engine oil into the engine oil system.

  • Page 38: Features And Controls

    If the engine is in the Warning condition, then the critical condition mode. event will be logged in the memory of the ECM. An event code will be transmitted over the Perkins Data The Electronic Control Module (ECM) monitors the link and the hard wired Warning output will be following parameters: energized.
  • Page 39 M0122761-03 Operation Section Sensors and Electrical Components When the Critical Protection Override feature is Note: The ECM cannot be reset by using the Reset active, the ECM will continue to run the engine in all input until the engine has stopped. shutdown conditions except for overspeed shutdown.
  • Page 40 M0122761-03 Operation Section Sensors Only Earlier Engine Sensor Views Illustration 42 g06595481 Typical example of an earlier engine (1) Coolant temperature sensor (3) Oil pressure sensor (2) Air inlet temperature sensor (4) Camshaft speed/timing sensor...
  • Page 41 M0122761-03 Operation Section Sensors Only Illustration 43 g06595495 Typical example of an earlier engine (5) Inlet manifold temperature sensor (9) Fuel pressure sensor after secondary (12) Barometer pressure sensor (not shown) (6) Inlet manifold pressure sensor fuel filter (13) Flywheel speed/timing sensor (7) Fuel pressure sensor after primary fuel (10) Fuel pressure sensor before secondary filters...
  • Page 42 M0122761-03 Operation Section Sensors Only Barometric Pressure Sensor Illustration 44 g06595502 Typical example of an earlier engine Wiring harness removed for clarity (12) Barometric pressure sensor...
  • Page 43 M0122761-03 Operation Section Sensors Only Later Engine Sensor Views Illustration 45 g07584729 Typical example of a later engine (1) Air inlet temperature sensor (2) Oil pressure sensor (3) Camshaft speed/timing sensor...
  • Page 44 M0122761-03 Operation Section Sensors Only Illustration 46 g07584649 Typical example of a later engine (4) Inlet manifold temperature sensor (8) Fuel pressure sensor after primary fuel (10) Fuel pressure sensor before secondary (5) Inlet manifold pressure sensor filters fuel filter (6) Coolant temperature sensor (9) Fuel pressure sensor after secondary (11) Fuel temperature sensor...
  • Page 45 M0122761-03 Operation Section Sensors and Electrical Components Barometric Pressure Sensor Illustration 47 g07586627 Typical example of a later engine (13) Barometric pressure sensor i09769843 Sensors and Electrical Components (Electrical Components) The engine view shown is a typical examples only.
  • Page 46 M0122761-03 Operation Section Electrical Components Illustration 48 g06641888 Typical example of an earlier engine (1) Injector wiring harness (3) Electric Priming Pump (EPP) with remote (5) Starter relay (2) Alternator switch (6) Starting motor (4) Electric Priming Pump (EPP) relay (7) Electronic Control Module (ECM)
  • Page 47 M0122761-03 Operation Section Electrical Components Illustration 49 g07584777 Typical example of a later engine (1) Injector wiring harness (3) Electric Priming Pump (EPP) with remote (5) Starting motor (2) Alternator switch (6) Electronic Control Module (ECM) (4) Starter relay...

  • Page 48: Engine Diagnostics

    Self-Diagnostics If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off, an Perkins Electronic Engines have the capability to intermittent fault may have occurred. If a fault has perform a self-diagnostics test. When the system...

  • Page 49: Engine Starting

    M0122761-03 Operation Section Engine Starting Engine Starting NOTICE Do not engage the starting motor when flywheel is turning. i10198326 If the engine fails to start within 15 seconds, release Before Starting Engine the starter switch or button and wait one minute to al- low the starting motor to cool before attempting to start the engine again.
  • Page 50 At temperatures of below −18 °C (−0.4 °F), refer to your Perkins distributor for more information. 4. Stop the engine. Inspect the engine for leaks from the fuel, coolant, and lubricating oil systems.

  • Page 51: Engine Operation

    Table 3 . Perkins recommends that annual • Ensure that the drive belts are correctly adjusted. testing is done at the maximum engine rated load for The drive belts should be in good condition.

  • Page 52: Engine Stopping

    • Discoloration of the fuel can occur in the engine fuel system and is acceptable as long as the fuel Note: Individual applications will have different meets the specifications in Perkins Diesel Engines control systems. Ensure that the shutoff procedures Fluids Recommendations, M0113102. Refer to are understood.

  • Page 53: Cold Weather Operation

    Fuel Related Components in Cold Weather Note: Only use grades of fuel that are recommended by Perkins. Refer to this Operation and Maintenance Manual, “Fluid Recommendations”. Fuel Tanks Properties of the diesel fuel can have a significant effect on the engine cold start capability. It is critical Condensation can form in partially filled fuel tanks.
  • Page 54 58° C (136.4° F). Note: Heat exchanger type fuel heaters should have a bypass provision to prevent overheating of the fuel in warm-weather operation. For further information on fuel heaters, consult your Perkins distributor .

  • Page 55: Maintenance Section

    M0122761-03 Maintenance Section Refill Capacities Maintenance Section Table 6 5008-30 Engine and Engine with Radiator Engine Only 48 L (12.7 US gal) Refill Capacities Engine and Radiator 140 L (37.0 US gal) i09814892 Fuel System Refill Capacities Refer to the OEM specifications for additional information on the capacity of the fuel system.
  • Page 56 Coolant is normally composed of three elements: • Corrosion Water, additives, and glycol. • Formation of mineral deposits Refer to Perkins Diesel Engines Fluids Recommendations, M0113102 for additional • Rust information that relates to coolant. • Scale Water •...
  • Page 57 M0122761-03 Maintenance Section General Coolant Information Table 8 Ethylene Glycol Concentration The following three glycol-based coolants are recommended for use in Perkins diesel engines: Freeze Boil Protection Concentration Protection Preferred – Perkins ELC −37° C (−29° F) 106° C (223° F) 50 Percent Acceptable –...
  • Page 58 • SAE Society Of Automotive Engineers Inc. ELC or ELI. Perkins recommends a 6 percent to 8 percent concentration of SCA in those cooling • ECF Engine Crankcase Fluid systems.
  • Page 59 M0122761-03 Maintenance Section Engine Oil Specification Commercial Oils NOTICE Perkins require the use of the following specifica- tion of engine oil. Failure to use the appropriate specification of engine oil will reduce the life of your engine. Table 10 Minimum Oil Specification for 5006A-E23TA, 5008A-E30TA,...
  • Page 60 For more information on wear metals, refer to Specifications, “Engine Oil Filter (Extended Oil Service)” or consult your Perkins distributor. • Tests are conducted to detect contamination of the oil by water, glycol, or fuel.

  • Page 61: Maintenance Recommendations

    Perkins engines are unable to identify all the factors which can contribute to severe service operation, due to individual applications. Consult your Perkins dealer or your Perkins distributor for the unique maintenance that is necessary for the engine.

  • Page 62: Maintenance Interval Schedule

    M0122761-03 Maintenance Section Maintenance Interval Schedule “ Fuel Injector - Inspect/Adjust“ ....100 i10199336 Maintenance Interval Schedule Every 750 Service Hours or 2 Years (50Hz Engines in Standby or Prior to Functional Load Test Applications) “...
  • Page 63 M0122761-03 Maintenance Section 50Hz Engines in Standby Applications “ Fuel System Primary Filter - Replace“ ..101 Every 2000 Service Hours “ Overhaul (Top End)“ ..... . 115 Every 3000 Service Hours “...

  • Page 64: Maintenance Interval Schedule

    M0122761-03 Maintenance Section Maintenance Interval Schedule “ Belts - Inspect/Adjust/Replace“....77 i10199904 Maintenance Interval Schedule “ Belts - Inspect/Adjust/Replace“....72 (Engines in Prime Power “...
  • Page 65 M0122761-03 Maintenance Section Engines in Prime Power Applications “ Water Pump - Inspect“..... 118 Every 15 000 Service Hours “ Overhaul (Top End)“ ..... . 115 Every 30 000 Service Hours “...

  • Page 66: Maintenance Interval Schedule

    M0122761-03 Maintenance Section Maintenance Interval Schedule “ Belts - Inspect/Adjust/Replace“....77 i10199906 Maintenance Interval Schedule “ Belts - Inspect/Adjust/Replace“....72 (Engines in Base Load “...
  • Page 67 M0122761-03 Maintenance Section Engines in Base Load Applications “ Water Pump - Inspect“..... 118 Every 20 000 Service Hours “ Overhaul (Top End)“ ..... . 115 Every 40 000 Service Hours “...

  • Page 68: Maintenance Interval Schedule (60Hz Engines In Standby Applications)

    M0122761-03 Maintenance Section Maintenance Interval Schedule “ Fuel Injector - Inspect/Adjust“ ....100 i10203085 Maintenance Interval Schedule Every 500 Service Hours or 2 Years (60Hz Engines in Standby or Prior to Functional Load Test Applications) “...
  • Page 69 M0122761-03 Maintenance Section 60Hz Engines in Standby Applications “ Fuel System Primary Filter - Replace“ ..101 Every 2000 Service Hours “ Overhaul (Top End)“ ..... . 115 Every 3000 Service Hours “...

  • Page 70: Aftercooler Core - Clean/Test

    205 kPa (30 psi) for cleaning purposes. 7. Inspect the aftercooler to ensure cleanliness. Contact your Perkins distributor to pressure test Note: The aftercooler is combined with the radiator. the aftercooler. If necessary, replace the The core of the aftercooler cannot be removed.

  • Page 71: Battery - Replace

    M0122761-03 Maintenance Section Alternator Pulley - Check i07213693 i02322315 Alternator Pulley - Check Battery - Replace 1. Isolate the electrical supply to the engine. Remove guard cover from alternator. Refer to Operation and Maintenance Manual, Belts- Inspect/Adjust/ Batteries give off combustible gases which can explode.

  • Page 72: Battery Electrolyte Level - Check

    M0122761-03 Maintenance Section Battery Electrolyte Level - Check i02747977 i09570426 Battery Electrolyte Level - Battery or Battery Cable - Check Disconnect When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge.
  • Page 73 M0122761-03 Maintenance Section Belts - Inspect/Adjust/Replace To check accurately the belt tension, a suitable gauge should be used. 1. Isolate the electrical supply to the engine. Illustration 54 g07602295 Typical example a later engine Adjust 1. Ensure that the electrical supply to the engine is isolated.

  • Page 74: Belts - Inspect/Adjust/Replace

    (Fan Drive V-Belts) - Remove and Install for more information. i09809805 Belts - Inspect/Adjust/Replace (5008A-E30TA, 5008C-E30TA, and 5008AC-E30TA Engines Only) Inspection 1. Isolate the electrical supply to the engine. 2. Visible inspect fan guards for ware or damage. Repair as necessary.
  • Page 75 Note: Check that the pulleys are securely fitted. Visually check pulleys for angular misalignment, composite misalignment, and axial misalignment. Refer to your Perkins distributor for more information. Adjustment 1. Ensure that the electrical supply to the engine is isolated. As required, remove the guards.
  • Page 76 Frequency that the Grease is Applied Perkins recommends that the grease is applied at the following service intervals: • For engines in base load and prime power applications - every 500 hours or 1 year •...

  • Page 77: Belts - Inspect/Adjust/Replace

    M0122761-03 Maintenance Section Belts - Inspect/Adjust/Replace 7. Stop the engine. Refer to Operation and Maintenance Manual, “Stopping the Engine” for the correct procedure. 8. Isolate the electrical supply to the engine. Remove the guards. 9. Loosen bolts (5) and loosen the locknut (4). 10.

  • Page 78: Cooling System Coolant (Elc) - Change

    • The fuel has entered the cooling system and the Isolate the electrical supply to the engine. coolant is contaminated. 1. Refer to “Inspection” for removing the belt guard Note: Refer to Perkins Diesel Engines Fluids covers. Recommendations, Coolant Recommendations 2. Loosen bolt (6) and loosen bolt (11). Push (General Maintenance) for more information on the alternator (5) towards engine.
  • Page 79 M0122761-03 Maintenance Section Cooling System Coolant (ELC) - Change Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This inspection is a good opportunity to replace the water pump, the water temperature regulator, and the hoses, if necessary.
  • Page 80 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 to remove any debris.
  • Page 81 (4) in the cylinder block. Cooling system air locks may result in engine damage. 4. Fill the cooling system with Perkins ELC. Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Maintenance Section) for more information on cooling system specifications.
  • Page 82 (1.3 US gal) per minute to avoid air locks. Cooling system air locks may result in engine damage. 5. Using a pump, fill the cooling system with Perkins ELC. Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Maintenance Section) for more information on cooling system specifications.

  • Page 83: Cooling System Coolant - Change

    25 mm (1.0 inch) of the bottom of the filler pipe. coolant is contaminated. • The fuel has entered the cooling system and the coolant is contaminated. Note: Refer to Perkins Diesel Engines Fluids Recommendations, Coolant Recommendations (General Maintenance) for more information on the service life of the recommended coolants.
  • Page 84 M0122761-03 Maintenance Section Cooling System Coolant - Change 1. Stop the engine and allow the engine to cool. Isolate the electrical supply to the engine. Loosen the cooling system filler cap (1) slowly to relieve any pressure. Remove the cooling system filler cap.
  • Page 85 When you recycle used engine cool- ant for reuse in engine cooling systems, the full distil- lation procedure is the only method acceptable by Perkins Engines Company LTD to reclaim the coolant. For information regarding the disposal and the recycling of used coolant, consult your Perkins distributor.
  • Page 86 M0122761-03 Maintenance Section Cooling System Coolant - Change NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks. Cooling system air locks may result in engine damage. 4. Fill the cooling system with coolant. Refer to the Operation and Maintenance Manual, “Fluid Recommendations”...
  • Page 87 M0122761-03 Maintenance Section Cooling System Coolant - Change 10. Install power to the engine. Start the engine. Operate the engine. Inspect the cooling system for leaks. Ensure that the cooling system operates at the correct temperature. Fill using a pump 1.

  • Page 88: Cooling System Coolant Level - Check

    M0122761-03 Maintenance Section Cooling System Coolant Level - Check Illustration 89 g06258129 10. Clean the cooling system filler cap (1) and inspect the seal (2). If the seal is damaged, discard the old filler cap and install a new filler cap. If the seal is not damaged, use a suitable pressurizing pump to pressure test the filler cap.

  • Page 89: Engine - Clean

    M0122761-03 Maintenance Section Driven Equipment - Check The viscous damper has a weight that is located NOTICE inside a fluid filled case. Inspect the damper for Accumulated grease and oil on an engine is a fire evidence of fluid leaks. If a fluid leak is found, hazard.

  • Page 90: Engine Air Cleaner Service Indicator - Inspect

    M0122761-03 Maintenance Section Engine Air Cleaner Service Indicator - Inspect Renew the air filter elements if the service indicators i02415251 are triggered. Refer to Operation and Maintenance Engine Air Cleaner Service Manual, “Engine Air cleaner Service Indicator - Inspect” for more information. Indicator - Inspect Some engines are equipped with air intake precleaners.

  • Page 91: Engine Crankcase Breather - Clean

    M0122761-03 Maintenance Section Engine Crankcase Breather - Clean Illustration 94 g01242332 When the air filter element requires replacement, the center section of the service indicator (1) is red. Service Indicator Reset Illustration 96 g06009120 Typical example 1. Isolate the electrical supply to the engine. 2.
  • Page 92 M0122761-03 Maintenance Section Engine Crankcase Breather - Clean/Replace Some applications may be equipped with a cold climate kit for the engine crankcase breather. If equipped, remove the cold climate kit before cleaning/ replacing the filter. Illustration 98 g07790162 Typical example 1.

  • Page 93: Engine Mounts - Inspect

    M0122761-03 Maintenance Section Engine Mounts - Inspect 3. Install the new filter element. Align the clips (4). NOTICE Install the bowl (1). Operating your engine when the oil level is above the “Max” mark could cause your crankshaft to dip into Connect the power supply to the engine.
  • Page 94 M0122761-03 Maintenance Section Engine Oil Level - Check Illustration 100 g06597046 Typical example of an earlier engine...

  • Page 95: Engine Oil Pump - Inspect

    1. Maintain the oil level between the “Min” mark (Y) worn or damaged. Alternatively, replace the engine and the “Max” mark (X) on the engine oil level oil pump. For more information consult your Perkins gauge (2), refer to Illustration 102 . Do not fill the distributor.

  • Page 96: Engine Oil Sample - Obtain

    Do not allow hot oil or hot components to develop a service program for the engine. contact the skin. Note: Perkins Engines Stafford must agree to the maintenance schedule. NOTICE Care must be taken to ensure that fluids are con-...
  • Page 97 If the engine is operated in severe service conditions, Perkins recommends the use of engine oil sampling. Refer to this Operation and Maintenance Manual, Engine Oil sample - Obtain for more information.

  • Page 98: Engine Protective Devices - Check

    M0122761-03 Maintenance Section Engine Protective Devices - Check Note: Ensure that the vessel that will be used is large NOTICE enough to collect the waste oil. If equipped with an auxiliary oil filter system or a re- mote filter system, follow the OEM or the filter manu- 2.

  • Page 99: Fan Drive Pulley - Check

    Only qualified service personel should perform this maintenance. Refer to the Service Manual or your au- thorized Perkins dealer or your Perkins distributor for 2. Remove the guards (not shown) to gain access to the complete valve lash adjustment procedure.

  • Page 100: Fuel System - Prime

    Use the following procedures to remove air from the dure to inspect or adjust the fuel injectors. fuel system. Operation of Perkins engines with fuel injectors that NOTICE have not been inspected or adjusted can reduce en- Do not crank the engine continuously for more than gine efficiency, and also reduce engine component 30 seconds.
  • Page 101 M0122761-03 Maintenance Section Fuel System Primary Filter - Replace i08246229 Fuel System Primary 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 102: Fuel System Primary Filter/Water Separator - Drain

    M0122761-03 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 10. Install new O ring seal (5) to the WIF sensor. 11. Install the WIF sensor. 12. If necessary, connect the WIF sensor to harness assembly (3) and install new cable strap (4). 13.

  • Page 103: Fuel System Secondary Filter - Replace

    Engine Control Module (ECM) uses the sensors to monitor the temperature and pressure of the fuel that is entering the engine. The electronic service tool (EST) can be used to monitor the fuel pressure. Contact Perkins distributor for more information. Illustration 112 g06650982...

  • Page 104: Fuel Tank Water And Sediment - Drain

    M0122761-03 Maintenance Section Fuel Tank Water and Sediment - Drain 10. Start the engine and run the engine. Check the Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel fuel system for leaks. supply pipe.
  • Page 105 (if equipped). The coolant system and the hoses for the coolant system are not always supplied by Perkins. The following text describes a typical method of replacing coolant hoses. Refer to the OEM information for further information on the coolant system and the hoses for the coolant system.
  • Page 106 M0122761-03 Maintenance Section Hoses and Clamps - Inspect/Replace 10. Start the engine. Inspect the cooling system for leaks. Clamps and V-Band Locations For 6 Cylinder Engines Illustration 114 g06642391 Typical example of an earlier engine (1) Clamp torque 7 N·m (62 lb in)
  • Page 107 M0122761-03 Maintenance Section Hoses and Clamps - Inspect/Replace Illustration 115 g07603376 Typical example of an earlier engine (2) Clamp torque 10 N·m (88.5 lb in)
  • Page 108 M0122761-03 Maintenance Section Hoses and Clamps - Inspect/Replace Illustration 116 g06329596 Typical example of an earlier engine (1) Clamp torque 7 N·m (62 lb in)
  • Page 109 M0122761-03 Maintenance Section Hoses and Clamps - Inspect/Replace Clamps and V-Band Locations For 8 Cylinder Engines Illustration 117 g06620523 Typical example of an earlier engine (1) Clamp torque 10 N·m (88.5 lb in)
  • Page 110 M0122761-03 Maintenance Section Hoses and Clamps - Inspect/Replace Illustration 118 g07603438 Typical example of an earlier engine (2) Clamp torque 10 N·m (88.5 lb in)
  • Page 111 M0122761-03 Maintenance Section Hoses and Clamps - Inspect/Replace Illustration 119 g06621529 Typical example of an earlier engine (1) Clamp torque 10 N·m (88.5 lb in)
  • Page 112 M0122761-03 Maintenance Section Hoses and Clamps - Inspect/Replace Clamps and V-Band Locations for Later Engines Illustration 120 g07591701 Typical example of a later engine (1) Clamp torque 10 N·m (88.5 lb in) (3) Clamp torque 7.5 N·m (66.4 lb in)
  • Page 113 M0122761-03 Maintenance Section Hoses and Clamps - Inspect/Replace Illustration 121 g07591715 Typical example of a later engine (3) Clamp torque 7.5 N·m (66.4 lb in) Illustration 122 g07591789 Typical example of a later engine (1) Clamp torque 7 N·m (62 lb in)

  • Page 114: Jacket Water Heater - Check

    M0122761-03 Maintenance Section Jacket Water Heater - Check Illustration 123 g07591726 Typical example of a later engine (2) Clamp torque 10 N·m (88.5 lb in) (3) Clamp torque 7.5 N·m (66.4 lb in) Clamps and V-Band Clamp Torques Check the operation of the jacket water heater. Check the operation of the circulation pump, if equipped.

  • Page 115: Overhaul (Top End)

    This measurement Monitor the engine as the engine accumulates provides an accurate indication of the rate of valve service hours. Consult Perkins Engines Stafford wear. This measurement can be used to predict about scheduling a major overhaul.

  • Page 116: Radiator - Clean

    Radiator - Clean Severe service is the application of an engine that exceeds the current published standards for that engine. Perkins maintains standards for the following Note: Adjust the frequency of cleaning according to engine parameters: the effects of the operating environment. The radiator and the aftercooler are a combined unit ensure that •...

  • Page 117: Starting Motor - Inspect

    • Operating at excessive loads Perkins engines are unable to identify all the factors • Operating at excessive speeds which can contribute to severe service operation, due to individual applications. Consult your Perkins •...

  • Page 118: Walk-Around Inspection

    A normal condition is replace a water pump. Refer to Operation and that a small amount of leakage to occur as the engine Maintenance Manual, “Water Pump - Inspect” for cools down and parts contract. more information. If necessary, consult your Perkins distributor.
  • Page 119 M0122761-03 Maintenance Section Water Pump - Inspect Visually inspect the water pumps for leaks. The water pumps are not serviceable items. Replace a leaking water pump. Refer to Disassembly and Assembly for more information.

  • Page 120: 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 121: Index

    Replace ............91 Belt) ............... 77 Closed Breather System......91 Adjustment........... 78 Engine Description .......... 28 Inspection ............ 77 Aftermarket Products and Perkins Replace the Belt .......... 78 Engines ............30 Burn Prevention..........16 Electronic Engine Features ......29 Batteries............17 Engine Service Life........
  • Page 122 Dispose of Waste Properly ......16 Fluid Penetration ......... 14 Fan Drive Pulley - Check (5008A-E30TA, Inhalation ............. 15 5008C-E30TA, and 5008AC-E30TA Pressurized Air and Water......14 Engines Only) ..........99 Static Electricity Hazard when Fueling with Fault Logging........... 48 Ultra-low Sulfur Diesel Fuel .......
  • Page 123 M0122761-03 Index Section Initial 750 Service Hours or 2 Years .... 62 Warning Alarm ..........38 When Required..........62 Mounting and Dismounting ......19 Maintenance Interval Schedule (60Hz Engines in Standby Applications) Daily or Prior to Starting Stand-by Unit..68 Operation Section..........
  • Page 124 M0122761-03 Index Section Later Engine Sensor Views ......43 Severe Service Application ......61 Environmental Factors......... 61 Incorrect Maintenance Procedures ..... 61 Incorrect Operating Procedures ....61 Severe Service Application - Check....116 Environmental Factors........117 Incorrect Maintenance Procedures ....117 Incorrect Operating Procedures ....117 Starting Motor - Inspect ........117 Starting the Engine..........
  • Page 125 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 126 M0122761 ©2024 Perkins Engines Company Limited All Rights Reserved June 2024...

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