Perkins 5012C-E46TA Operation And Maintenance Manual
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Perkins 5012C-E46TA Operation And Maintenance Manual

Perkins 5012C-E46TA Operation And Maintenance Manual

Industrial engine
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M0163009 (en-us)
October 2024
Operation and
Maintenance
Manual
5012C-E46TA Industrial Engine

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  • Page 1 M0163009 (en-us) October 2024 Operation and Maintenance Manual 5012C-E46TA Industrial Engine...

  • Page 2: Important Safety Information

    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

    M0163009 Table of Contents Table of Contents Maintenance Section Refill Capacities..........50 Foreword ............4 Maintenance Recommendations ....56 Safety Section Maintenance Interval Schedule....... 57 Safety Messages..........6 Warranty Section Additional Messages ........11 Warranty Information........100 General Hazard Information......12 Index Section Burn 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: Maintenance Intervals

    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.
  • Page 7 M0163009 Safety Section Safety Messages Warning labels Position Bank A Illustration 1 g07673876 Typical example (1) Universal warning label locations (3) Electrocution danger label location (5) Hot fluid under pressure label locations (2) Do not step label location (4) Hot surface label location (6) Ether warning label location...

  • Page 8: Universal Warning

    M0163009 Safety Section Safety Messages Warning Labels Position Bank B Illustration 2 g07671804 Typical example (1) Universal warning label locations (4) Hot surface label location (6) Ether warning label location (2) Do not step label location (5) Hot fluid under pressure label locations (3) Electrocution danger label location (not shown) Universal Warning...

  • Page 9: Hot Surface

    M0163009 Safety Section Safety Messages Hot Surface Illustration 4 g01393287 Do not use this surface as a step or platform. This Illustration 6 g01372256 surface may not support additional weight or may be slippery. Serious injury or death could occur from a fall.

  • Page 10: Ether Warning

    The hot fluids under pressure labels (5) have two the engine oil cooler. positions. One label is on the end cover of the oil cooler. Perkins recommends that the other hot fluid under pressure label is installed on the radiator, next Hot Fluid Under Pressure to the coolant filler cap.

  • Page 11: Additional Messages

    M0163009 Safety Section Additional Messages Ether warning label (6) is on the support bracket for The rotating shaft hand crush hazard label is on the the air cleaners. cover of the crankshaft vibration damper. Rotating Shaft Hand Crush Hazard i09968095 Additional Messages Illustration 10 g06249496...

  • Page 12: General Hazard Information

    M0163009 Safety Section General Hazard Information i09915008 General Hazard Information Illustration 14 g00104545 Illustration 12 g07674434 Attach a “Do Not Operate” warning tag or a similar Typical example of bank B warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired.
  • Page 13 • For initial start-up of a new engine or for starting an engine that has been serviced, make • Perkins recommend that you do not stand next to provisions to stop the engine if an overspeed an exposed running engine unless it is necessary occurs.

  • Page 14: Pressurized Air And Water

    M0163009 Safety Section General Hazard Information • Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment. Pressurized Air and Water Pressurized air and/or water can cause debris and/or hot water to be blown out.

  • Page 15: Asbestos Information

    (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: Dispose Of Waste Properly

    M0163009 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: Diesel Fuel

    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: Fire Extinguisher

    M0163009 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 21 g00704135 Gases from a battery can explode.

  • Page 19: Crushing Prevention And Cutting Prevention

    Do not install any lines that are damaged. i09912199 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

    M0163009 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

    M0163009 Product Information Section Model Views Product Information Section Model Views i10021262 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 22 g07703218 Typical example (1) Engine air cleaners...
  • Page 23 M0163009 Product Information Section Model View Illustrations (11) Oil pressure relief valve screw (14) Twin secondary fuel filters (17) Starting motor (12) Fuel transfer pump (15) Engine oil cooler (1 of 2) (18) Electronic control module (1 of 2) (13) Oil drain plug (1 of 2) (16) Oil filters Illustration 23 g07703681...
  • Page 24 M0163009 Product Information Section Model View Illustrations Illustration 24 g07703760 Typical example with radiator removed (4) Breather (1 of 2) (26) Oil drain plug (2 of 2) (29) Thermostat housing (20) Breather (2 of 2) (28) Water pumps (30) Crankshaft damper...

  • Page 25: Engine Description

    The left and the right sides of the engine are determined from the flywheel end. Bank A cylinders are on the right-hand side of The Perkins 5012C-E46TA Industrial Engines have the engine. Bank B cylinders are on the left-hand side the following characteristics: of the engine.
  • Page 26 Cold Engines Rotation (flywheel end) Counterclockwise Air-to-air aftercooled Perkins does not warrant the quality or performance of non-Perkins fluids and filters. Electronic Engine Features When auxiliary devices, accessories, or consumables (filters, additives, catalysts) which are The engine is designed for electronic controls. The...

  • Page 27: Product Identification Information

    Illustration 27 g07694551 Typical example Your Perkins distributor needs all the number from these labels when service information is required. (1) Engine serial number and ratings labels location (2) Engine serial number plate (if installed) (3) Emission label location...
  • Page 28 M0163009 Product Information Section Plate Locations and Film Locations Illustration 31 g06646849 Typical example of Emissions label...

  • Page 29: Operation Section

    If alterations are made, ensure that correct lifting devices are provided. Consult your Perkins distributor for information regarding fixtures for correct engine lifting. The radiator and the engine are to be disassembled...
  • Page 30 M0163009 Operation Section Product Lifting Illustration 32 g07693840 Typical example Some parts are removed for clarity (1) Rear lifting eye on A Bank (2) Front lifting eye on B Bank...
  • Page 31 M0163009 Operation Section Product Lifting Illustration 33 g07693844 Typical example Some parts are removed for clarity (3) Front lifting eye on A Bank (4) Rear lifting eye on B Bank...

  • Page 32: Product Storage

    The engine must be stored in a water proof building. The building must be kept at a constant temperature. 3. Apply lubricant to all points in this Operation and Engines that are filled with Perkins ELC will have Maintenance Manual, “Maintenance Interval coolant protection to an ambient temperature of Schedule”.

  • Page 33: Coolant System

    Completely fill the cooling system before storage. Use a bar or a turning tool to turn over the engine Refer to “Perkins Diesel Engines Fluids slowly. This procedure puts the oil on the cylinder Recommendations”M0113102 for more information walls.
  • Page 34 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 35: 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 36: Sensors And Electrical Components

    M0163009 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 37 M0163009 Operation Section Sensors and Electrical Components Engine Sensor Views Illustration 35 g07720178 Typical example of the sensor locations on the left side of the engine (1) Coolant temperature sensor (4) Electronic Control Module (ECM) (7) Inlet manifold air pressure sensor (2) Air inlet temperature sensor (5) Engine oil pressure sensor (3) Flywheel speed sensor...
  • Page 38 M0163009 Operation Section Sensors and Electrical Components Illustration 36 g07720196 Typical example of the close up views of sensor locations on the left side of the engine (1) Coolant temperature sensor (4) Electronic Control Module (ECM) (7) Inlet manifold air pressure sensor (2) Air inlet temperature sensor (5) Engine oil pressure sensor (3) Flywheel speed sensor...
  • Page 39 M0163009 Operation Section Sensors and Electrical Components Illustration 37 g07720216 Typical example of the sensor locations on the right side of the engine (1) Coolant temperature sensor (8) Camshaft gear speed sensor (12) Fuel temperature sensor (2) Air inlet temperature sensor (9) Fuel pressure sensor (secondary fuel (13) Atmospheric pressure sensor (4) Electronic Control Module (ECM)

  • Page 40: Engine Electrical Components

    M0163009 Operation Section Sensors and Electrical Components Illustration 38 g07720247 Typical example of the close up views of sensor locations on the right side of the engine (6) Inlet manifold temperature sensor (9) Fuel pressure sensor (secondary fuel (12) Fuel temperature sensor (7) Inlet manifold air pressure sensor filter) (13) Atmospheric pressure sensor...
  • Page 41 M0163009 Operation Section Sensors and Electrical Components Illustration 39 g07706955 Typical example of the right side of the engine (1) Injector wiring harness (3) Electric Priming Pump (EPP) with remote (5) Starting motor (2) Alternator switch (6) Electronic Control Module (ECM) (4) Electric Priming Pump (EPP) relay...
  • Page 42 M0163009 Operation Section Sensors and Electrical Components Illustration 40 g07706967 Typical example of the left side of the engine (7) Injector wiring harness (8) Electronic Control Module (ECM)

  • Page 43: 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 44: Engine Starting

    M0163009 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 45: Cold Weather Starting

    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 46: Engine Operation

    75 percent. Finally, between 30 and 45 minutes, increase the load to the full rated load for the engine. On engines with low load profiles, Perkins recommends that a regular oil sample analysis is carried out and if required the oil and oil filters are changed.

  • Page 47: 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 48: 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 49 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 50: Maintenance Section

    Table 3 proper operating temperature. Cooling system prob- lems develop without water temperature 5012C-E46TA Engine with Radiator regulators. Engine Only 73 L (19.29 US gal) Clean the cooling system for the following reasons: • Contamination of the cooling system (continued) •...
  • Page 51 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 52: Coolant Recommendations

    M0163009 Maintenance Section General Coolant Information Table 5 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 53: Engine Oil

    • 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 54 M0163009 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 7 Minimum Oil Specification for 5006A-E23TA, 5008A-E30TA,...

  • Page 55: Oil Analysis

    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 56: 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 57: Maintenance Interval Schedule

    M0163009 Maintenance Section Maintenance Interval Schedule “ Belts - Inspect/Adjust/Replace“....61 i09907794 Maintenance Interval Schedule “ Belts - Inspect/Adjust/Replace“....63 “...
  • Page 58 M0163009 Maintenance Section Maintenance Interval Schedule “ Turbocharger - Inspect“ ..... 98 “ Water Pump - Inspect“..... . 99...

  • Page 59: 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 60: Battery - Replace

    M0163009 Maintenance Section Alternator Pulley - Check i07213693 i09652189 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 61: Battery Electrolyte Level - Check

    M0163009 Maintenance Section Battery Electrolyte Level - Check 9. Connect the NEGATIVE “-” cable to the i09570426 NEGATIVE “-” battery terminal. Battery or Battery Cable - Disconnect i02747977 Battery Electrolyte Level - Check The battery cables or the batteries should not be When the engine is not run for long periods of time or removed with the battery cover in place.
  • Page 62 M0163009 Maintenance Section Alternator Belt Illustration 44 g07693497 Illustration 46 g07693494 5. Apply 4.3 to 8.7 N (1 to 1.9 lb) of pressure at point (X). The total deflection should not exceed 2.75 mm (0.10 inch). Replace the belt if the total deflection exceeds 1.5 mm (0.06 inch).

  • Page 63: Belts - Inspect/Adjust/Replace

    M0163009 Maintenance Section Belts - Inspect/Adjust/Replace 4. If necessary, install bolt (11) and tension the new 2. Visually inspect fan guards for wear or damage. belt. Refer to “Inspection” for more information. Repair as necessary. Remove the fan guard (1). 5.
  • Page 64 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. Remove the fan guards as required.

  • Page 65: Cooling System Coolant (Elc) - Change

    - Change generator set. Frequency that the Grease is Applied NOTICE Perkins recommends that the grease is applied at the Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte- following service intervals: nance, testing, adjusting and repair of the product.
  • Page 66 M0163009 Maintenance Section Cooling System Coolant (ELC) - Change Drain 2. 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 Pressurized System: Hot coolant can cause seri- pressure test the filler cap.
  • Page 67 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 68 (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 Perkins (ELC). Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Maintenance Section) for more information on cooling system specifications.
  • Page 69 M0163009 Maintenance Section Cooling System Coolant (ELC) - Change Illustration 59 g06258129 11. 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 70: Cooling System Coolant - Change

    Cooling system air locks may result in engine leaks. Ensure that the cooling system operates at damage. the correct temperature. 5. Using a pump, fill the cooling system with Perkins i09981919 (ELC). Refer to the Operation and Maintenance Cooling System Coolant - Manual, “Fluid Recommendations”...
  • Page 71 • The oil has entered the cooling system and the 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 72 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 73 M0163009 Maintenance Section Cooling System Coolant - Change Illustration 69 g07693484 Illustration 71 g07821239 Typical example of Bank A Typical example of Bank A water temperature regulator Illustration 70 g07693475 Illustration 72 g07821251 Typical example of Bank B Typical example of Bank B water temperature regulator 2.
  • Page 74 M0163009 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 Illustration 73 g06258129...
  • Page 75 M0163009 Maintenance Section Cooling System Coolant - Change Illustration 75 g07693475 Illustration 77 g07821251 Typical example of Bank B Typical example of Bank B water temperature regulator 3. Remove the drain plug (4) on bank A engine oil 4. Remove the plug (6) on the water temperature cooler and drain plug (5) on bank B engine oil regulator on bank A and plug (7) on the water cooler to allow air in the cooling system to vent to...

  • Page 76: Cooling System Coolant Level - Check

    M0163009 Maintenance Section Cooling System Coolant Level - Check Note: Ensure that the filler cap is installed before operating the engine. 10. Install power to the engine. Start the engine. Operate the engine to purge the air from the cavities of the engine block. Use the normal shutdown procedure to stop the engine.

  • Page 77: Engine - Clean

    M0163009 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 78: Engine Air Cleaner Service Indicator - Inspect

    M0163009 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 79: Service Indicator Reset

    M0163009 Maintenance Section Engine Crankcase Breather - Clean Illustration 83 g01242332 When the air filter element requires replacement, the center section of the service indicator (1) is red. Service Indicator Reset Illustration 85 g02775881 Typical example 2. Remove the wing nut (1) and the cover (2). 3.
  • Page 80 M0163009 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 87 g07790162 Typical example 1.

  • Page 81: Engine Mounts - Inspect

    M0163009 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 82: Engine Oil Sample - Obtain

    Replace any components that are worn or damaged. Alternatively, replace the engine Ensure that the container for the sample is clean and oil pump. For more information consult your Perkins dry. Also ensure that the container for the sample is distributor.

  • Page 83: Drain The Engine Lubricating Oil

    If the engine is operated in severe service conditions, 3. Install one end of suitable tubing to the drain valve Perkins recommends the use of engine oil sampling. (8) on the engine oil cooler. Place the other end of Refer to this Operation and Maintenance Manual, Engine Oil sample - Obtain for more information.

  • Page 84: Fill The Oil Pan

    4. Stop the engine and allow the oil to drain back to vent possible damage to the engine. the oil pan for a minimum of 10 minutes. To prevent damage to the engine, only authorized service personnel or your Perkins dealer should perform the tests.

  • Page 85: Visual Inspection

    Only qualified service personel should perform this Typical example maintenance. Refer to the Service Manual or your au- thorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure. 2. Remove the guards (not shown) to gain access to the fan drive pulley (1).

  • Page 86: Fuel System - Prime

    Perkins distributor for the complete proce- minutes before cranking the engine again. dure to inspect or adjust the fuel injectors. Operation of Perkins engines with fuel injectors that have not been inspected or adjusted can reduce en- gine efficiency, and also reduce engine component life.

  • Page 87: Fuel System Primary Filter - Replace

    M0163009 Maintenance Section Fuel System Primary Filter - Replace i09996070 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 88: Fuel System Primary Filter/Water Separator - Drain

    1. Place a suitable container under the fuel filters (1) The electronic service tool (EST) can be used to to catch any fuel that might spill. Clean up any monitor the fuel pressure. Contact Perkins distributor spilled fuel. for more information.

  • Page 89: Fuel Tank Water And Sediment - Drain

    M0163009 Maintenance Section Fuel Tank Water and Sediment - Drain i02335436 Fuel Tank Water and Sediment - Drain NOTICE Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte- nance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable contain- ers before opening any compartment or disassem- bling any component containing fluids.

  • Page 90: Hoses And Clamps - Inspect/Replace

    The coolant system and the hoses for the coolant penetration and burn hazards. High pressure fuel system are not always supplied by Perkins. The spray may cause a fire hazard. Failure to follow following text describes a typical method of replacing these inspection, maintenance and service in- coolant hoses.
  • Page 91 M0163009 Maintenance Section Hoses and Clamps - Inspect/Replace Pressurized System: Hot coolant can cause seri- ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
  • Page 92 M0163009 Maintenance Section Hoses and Clamps - Inspect/Replace 10. Start the engine. Inspect the cooling system for leaks. Clamps and V-Band Locations Illustration 100 g07710889 (1) Clamp torque 10 N·m (88.5 lb in) (1 of 4) (3) Clamp torque 7.5 N·m (66.4 lb in) (1 of (5) Clamp torque 7.5 N·m (66.4 lb in) (1 of (2) Clamp torque 10 N·m (88.5 lb in) (1 of 4) (4) Clamp torque 7 N·m (62 lb in) (1 of 2)

  • Page 93: Jacket Water Heater - Check

    M0163009 Maintenance Section Jacket Water Heater - Check Illustration 101 g07711270 (6) Clamp torque 7 N·m (62 lb in) (8) Clamp torque 7 N·m (62 lb in) (7) Clamp torque 7 N·m (62 lb in) (9) Clamp torque 7 N·m (62 lb in) (1 of 4) Clamps and V-Band Clamp Torques (Table 9, contd) 7 N·m (62 lb in)

  • Page 94: Overhaul (Top End)

    Contact your Perkins distributor for more information. Check the operation of the circulation pump, if An inspection of the components by the Perkins equipped. For ambient temperatures of 10 °C (50 °F) distributor can help to determine when a major and below, maintain the heater should maintain the overhaul is required as well as the other factors.

  • Page 95: Top End Overhaul Information

    During a top end overhaul, one piston should For more information contact Perkins distributor. be removed. Inspect the piston, piston rings, and the cylinder liner. The condition of these components will i09909128 determine the period of the major overhaul.
  • Page 96 • Frequent hot shutdowns service life. • Operating at excessive loads Perkins engines are unable to identify all the factors which can contribute to severe service operation, due • Operating at excessive speeds to individual applications. Consult your Perkins distributor or your Perkins distributor for the unique •...

  • Page 97: Speed Sensor - Clean/Inspect

    Starting Motor - Inspect Illustration 102 g07698725 Perkins recommends a scheduled inspection of the Typical example starting motor. If the starting motor fails, the engine may not start in an emergency situation. 2. Disconnect connector (1) from harness (2).

  • Page 98: Turbocharger - Inspect

    If leaking is observed, find the source and information on the checking procedure and for correct the leak. If leaking is suspected, check the flu- specifications or consult your Perkins distributors for id levels more often than recommended until the leak assistance.

  • Page 99: Water Pump - Inspect

    M0163009 Maintenance Section Water Pump - Inspect Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt could cause the belt to break.

  • Page 100: 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 101: Index

    Belts - Inspect/Adjust/Replace (Alternator Closed Breather System (If equipped) ..79 Belt) ............... 61 Engine Description .......... 25 Adjustment........... 62 Aftermarket Products and Perkins Inspection ............ 61 Engines ............26 Replace the Belt .......... 62 Electronic Engine Features ......26 Burn Prevention..........
  • Page 102 M0163009 Index Section Pressurized Air and Water......14 Static Electricity Hazard when Fueling with Fan Drive Pulley - Check......... 85 Ultra-low Sulfur Diesel Fuel ....... 14 Fault Logging........... 43 Features and Controls........35 Fire Prevention and Explosion Prevention..17 Ether ............18 Hoses and Clamps - Inspect/Replace.....
  • Page 103 M0163009 Index Section Environmental Factors......... 96 Incorrect Maintenance Procedures ..... 96 Operation Section..........29 Incorrect Operating Procedures ....96 Overhaul (Major) ..........94 Speed Sensor - Clean/Inspect ......97 Major Overhaul Information ......94 Speed Sensor ..........97 Scheduling a Major Overhaul ...... 94 Starting Motor - Inspect ........

  • Page 105: Product Information

    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 106 M0163009 ©2024 Perkins Engines Company Limited All Rights Reserved October 2024...

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