Perkins 1103 &1104 Series

WORKSHOP MANUAL

Operation and Maintenance

3 and 4 cylinder, naturally aspirated, and turbocharged

diesel engines for agricultural and industrial use

Publication SEBU7833-00
© Proprietary information of Perkins Engines Company Limited 2004, all rights reserved.
The information is correct at the time of print.
Published by Technical Publications.
Perkins Engines Company Limited, Peterborough, PE1 5NA, England
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. 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 the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents Warranty Section

Warranty Information ............................................ 70
Foreword ................................................................. 4
Index Section
Safety Section
Index ..................................................................... 71
Safety Signs and Labels ......................................... 6

General Hazard Information ................................... 6

Burn Prevention ...................................................... 8

Fire Prevention and Explosion Prevention .............. 8

Crushing Prevention and Cutting Prevention ........ 10

Mounting and Dismounting ................................... 10

Before Starting Engine .......................................... 10

Engine Starting ..................................................... 11

Engine Stopping ................................................... 11

Electrical System .................................................. 11

Product Information Section

Model Views ......................................................... 13

Product Identification Information ........................ 19

Operation Section
Lifting and Storage ................................................ 21

Gauges and Indicators .......................................... 24

Engine Starting ..................................................... 25

Engine Operation .................................................. 28

Engine Stopping ................................................... 29

Cold Weather Operation ....................................... 30

Maintenance Section
Lubricant Specifications ........................................ 34

Fuel Specifications ................................................ 39

Cooling System Specifications ............................. 42

Refill Capacities .................................................... 44

Maintenance Interval Schedule ............................ 46

4
Foreword

Foreword
Literature Information
This manual contains safety, operation instructions, Recommended service should be per formed
lubrication and maintenance infor mation. This at the appr opriate intervals as indicated in
manual should be stored in or near the engine area the Maintenance Interval Schedule. The actual
in a literatur e holder or literatur e storage area. Read, operating envir onment of the engine also gover ns
study and keep it with the literatur e and engine the Maintenance Interval Schedule. Therefore,
infor mation. under extremely sever e, dusty, wet or freezing cold
operating conditions, more frequent lubrication and
English is the prima ry language for all Perkins maintenance than is specified in the Maintenance
publications. The English used facilitates translation Interval Schedule may be necessar y.
and consistency in electr onic media deliver y.
The maintenance schedule items are organized
Some photographs or illustrations in this manual for a preventive maintenance management
show details or attachments that may be different program. If the preventive maintenance program
from your engine. Guards and covers may have is followed, a periodic tune-up is not requir ed.
been removed for illustrative purposes. Continuing The implementation of a preventive maintenance
improvement and advancement of product design management program should minimize operating
may have caused changes to your engine which are costs through cost avoidances resulting from
not included in this manual. Whenever a question reductions in unscheduled downtime and failur es.
arises regar ding your engine, or this manual, please
consult with your Perkins dealer or your Perkins
distributor for the latest available information.

Safety Maintenance Intervals

This safety section lists basic safety precautions. Perform maintenance on items at multiples
In addition, this section identifies hazar dous, of the original requi rement.
warning situations. Read and understand the basic We recommend that the maintenance schedules
precautions listed in the safety section before be reproduced and displayed near the engine as
operating or per forming lubrication, maintenance a convenient reminder. We also recommend that a
and repair on this product. maintenance record be maintained as part of the
engineís permanent record.
Operation Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
Operating techniques outlined in this manual are
maintenance schedule to meet the needs of your
basic. They assist with developing the skills and
operating envir onment.
techniques requir ed to operate the engine more
efficiently and economically . Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.

The operation section is a reference for operators.

Photographs and illustrations guide the operator Overhaul
through procedur es of inspecting, starting,
operating and stopping the engine. Major engine overhaul details are not cover ed in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Maintenance Major repairs should only be carried out by
Perkins authorized per sonnel . Your Perkins dealer or
The maintenance section is a guide to engine your Perkins distributor offer a variety of options
care. The illustrated, step-by-step instructions are regarding overhaul programs. If you experience a
grouped by service hours and/or calendar time major engine failure, there are also numerous after
maintenance intervals. Items in the maintenance failure overhaul options available .
schedule are referenced to detailed instructions Consult your Perkins dealer or your Perkins
that follow. distributor for information regarding these options.
 5
Foreword

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.

Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.
6
Safety Section
Safety Signs and Labels

Safety Section Ether

The warning label for ether is located on the top,
i01841322 the front, the rear, or the side of the engine.

Safety Signs and Labels

There may be several specific warning signs on

an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiar with all warning
signs.

Ensure that all of the warning signs are legible.

Clean the warning signs or replace the warning
signs if the words cannot be read or if the pictures
are not visible. When the warning signs are
g00640926
cleaned, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
Never spray Ether starting aids into the air inlet.
the warning signs. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures
the warning signs. The warning signs that are i01884947
loosened could drop off of the engine.
General Hazard Information
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. Perkins dealers or
Perkins distributors can provide new warning signs.

Do not work on the engine and do not operate the

engine unless the instructions and warnings in the
Operation and Maintenance Manual are understood.
Proper care is your responsibility. Failure to follow
the instructions or failure to heed the warnings
could result in injury or in death.

The warning labels that may be found on the engine

are illustrated and described.

g00104545
Illustration 1

Attach a “Do Not Operate” warning tag or a similar

warning tag to the start switch or to the controls
before you service the equipment or before you
repair the equipment.
 7
Safety Section
General Hazard Information

The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be
below 275 kPa (40 psi).

Fluid Penetration
Pressure can be trapped in the hydraulic circuit
long after the engine has been stopped. The
pressure can cause hydraulic fluid or items such
as pipe plugs to escape rapidly if the pressure is
not relieved correctly.

Do not remove any hydraulic components or parts

Illustration 2 g00702020 until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
Wear a hard hat, protective glasses, and other components or parts until pressure has been
protective equipment, as required. relieved or personal injury may occur. Refer to
the OEM information for any procedures that are
Do not wear loose clothing or jewelry that can snag required to relieve the hydraulic pressure.
on controls or on other parts of the engine.

Make sure that all protective guards and all covers

are secured in place on the engine.

Keep the engine free from foreign material. Remove

debris, oil, tools, and other items from the deck,
from walkways, and from steps.

Never put maintenance fluids into glass containers.

Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report all g00687600

necessary repairs. Illustration 3

Do not allow unauthorized personnel on the Always use a board or cardboard when you check
equipment. for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
Unless you are instructed otherwise, perform serious injury and possible death. A pin hole leak
maintenance on the engine with the equipment in can cause severe injury. If fluid is injected into your
the servicing position. Refer to the OEM information skin, you must get treatment immediately. Seek
for the procedure for placing the equipment in the treatment from a doctor that is familiar with this type
servicing position. of injury.

Pressure Air and Water Containing Fluid Spillage

Pressurized air and/or water can cause debris Care must be taken in order to ensure that fluids
and/or hot water to be blown out. This could result are contained during performance of inspection,
in personal injury. maintenance, testing, adjusting and repair of the
engine. Make provision to collect the fluid with
When pressurized air and/or water is used for a suitable container before any compartment is
cleaning, wear protective clothing, protective shoes, opened or before any component is disassembled.
and eye protection. Eye protection includes goggles
or a protective face shield. • Only use the tools that are suitable for collecting
fluids and equipment that is suitable for collecting
fluids.
8
Safety Section
Burn Prevention

• Only use the tools that are suitable for containing i01885715
fluids and equipment that is suitable for containing
fluids. Fire Prevention and Explosion
Obey all local regulations for the disposal of liquids.
Prevention

i01480768

Burn Prevention

Do not touch any part of an operating engine.

Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.

Coolant Illustration 4
g00704000

When the engine is at operating temperature, the All fuels, most lubricants, and some coolant mixtures
engine coolant is hot. The coolant is also under are flammable.
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
Any contact with hot coolant or with steam a fire. Fire may cause personal injury and property
can cause severe burns. Allow cooling system damage.
components to cool before the cooling system is
drained. A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
Check the coolant level after the engine has an emergency shutdown.
stopped and the engine has been allowed to cool.
Determine whether the engine will be operated in
Ensure that the filler cap is cool before removing an environment that allows combustible gases to be
the filler cap. The filler cap must be cool enough drawn into the air inlet system. These gases could
to touch with a bare hand. Remove the filler cap cause the engine to overspeed. Personal injury,
slowly in order to relieve pressure. property damage, or engine damage could result.
Cooling system conditioner contains alkali. Alkali If the application involves the presence of
can cause personal injury. Do not allow alkali to combustible gases, consult your Perkins dealer
contact the skin, the eyes, or the mouth. and/or your Perkins distributor for additional
information about suitable protection devices.
Oils
Remove all flammable materials such as fuel, oil,
Hot oil and hot lubricating components can cause and debris from the engine. Do not allow any
personal injury. Do not allow hot oil to contact the flammable materials to accumulate on the engine.
skin. Also, do not allow hot components to contact
the skin. Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
Batteries containers. Do not smoke in areas that are used for
storing flammable materials.
Electrolyte is an acid. Electrolyte can cause
personal injury. Do not allow electrolyte to contact Do not expose the engine to any flame.
the skin or the eyes. Always wear protective glasses
for servicing batteries. Wash hands after touching
the batteries and connectors. Use of gloves is
recommended.
 9
Safety Section
Fire Prevention and Explosion Prevention

Exhaust shields (if equipped) protect hot exhaust Use caution when you are refueling an engine. Do
components from oil or fuel spray in case of a line, not smoke while you are refueling an engine. Do
a tube, or a seal failure. Exhaust shields must be not refuel an engine near open flames or sparks.
installed correctly. Always stop the engine before refueling.

Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.

Wiring must be kept in good condition. All electrical

wires must be properly routed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate
the engine. Clean all electrical connections and
tighten all electrical connections.

Eliminate all wiring that is unattached or

unnecessary. Do not use any wires or cables that
are smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing g00704135
Illustration 6
or sparking.
Gases from a battery can explode. Keep any open
Inspect all lines and hoses for wear or for
flames or sparks away from the top of a battery. Do
deterioration. The hoses must be properly routed.
not smoke in battery charging areas.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
Never check the battery charge by placing a metal
recommended torque. Leaks can cause fires.
object across the terminal posts. Use a voltmeter or
a hydrometer.
Oil filters and fuel filters must be properly installed.
The filter housings must be tightened to the proper
Improper jumper cable connections can cause
torque.
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.

Do not charge a frozen battery. This may cause

an explosion.

The batteries must be kept clean. The covers (if

equipped) must be kept on the cells. Use the
recommended cables, connections, and battery
box covers when the engine is operated.

Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

g00704059
Illustration 5
10
Safety Section
Crushing Prevention and Cutting Prevention

Lines, Tubes and Hoses Chips or other debris may fly off objects when
objects are struck. Before objects are struck, ensure
Do not bend high pressure lines. Do not strike high that no one will be injured by flying debris.
pressure lines. Do not install any lines that are bent
or damaged.
i01372247

Repair any lines that are loose or damaged. Leaks

can cause fires. Consult your Perkins dealer for
Mounting and Dismounting
repair or for replacement parts.

Check lines, tubes and hoses carefully. Do not Inspect the steps, the handholds, and the work
use your bare hand to check for leaks. Use a area before mounting the engine. Keep these items
board or cardboard to check for leaks. Tighten all clean and keep these items in good repair.
connections to the recommended torque.
Mount the engine and dismount the engine only at
Replace the parts if any of the following conditions locations that have steps and/or handholds. Do not
are present: climb on the engine, and do not jump off the engine.
• End fittings are damaged or leaking. Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
• Outer coverings are chafed or cut. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use
• Wires are exposed. any controls as handholds.
• Outer coverings are ballooning. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
• Flexible part of the hoses are kinked. platform. Secure the climbing equipment so that the
equipment will not move.
• Outer covers have embedded armoring.
Do not carry tools or supplies when you mount the
• End fittings are displaced. engine or when you dismount the engine. Use a
hand line to raise and lower tools or supplies.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other i01805780
parts, and excessive heat.
Before Starting Engine
i01359666

Crushing Prevention and NOTICE

Cutting Prevention For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
Support the component properly when work air and/or fuel supply to the engine.
beneath the component is performed.

Unless other maintenance instructions are provided, Overspeed shutdown should occur automatically.
never attempt adjustments while the engine is If automatic shutdown does not occur, press the
running. emergency stop button in order to cut the fuel
and/or air to the engine.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance Inspect the engine for potential hazards.
is performed. After the maintenance is performed,
reinstall the guards. Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
Keep objects away from moving fan blades. The area is free of personnel.
fan blades will throw objects or cut objects.
If equipped, ensure that the lighting system for the
When objects are struck, wear protective glasses in engine is suitable for the conditions. Ensure that all
order to avoid injury to the eyes. lights work properly, if equipped.
 11
Safety Section
Engine Starting

All protective guards and all protective covers must Engine exhaust contains products of combustion
be installed if the engine must be started in order which can be harmful to your health. Always start the
to perform service procedures. To help prevent an engine and operate the engine in a well ventilated
accident that is caused by parts in rotation, work area. If the engine is started in an enclosed area,
around the parts carefully. vent the engine exhaust to the outside.

Do not bypass the automatic shutoff circuits. Do not Note: The engine is equipped with an automatic
disable the automatic shutoff circuits. The circuits device for cold starting for normal conditions of
are provided in order to help prevent personal operation. If the engine will be operated in very
injury. The circuits are also provided in order to help cold conditions, then an extra cold starting aid may
prevent engine damage. be required. Normally, the engine will be equipped
with the correct type of starting aid for your region
See the Service Manual for repairs and for of operation.
adjustments.
The 1104 engine is equipped with a glow plug
starting aid in each individual cylinder that heats
i01929329
the air to improve starting.
Engine Starting
i01928905

Engine Stopping

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and Stop the engine according to the procedure in
personal injury. the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
If a warning tag is attached to the engine start the engine components.
switch or to the controls, DO NOT start the engine
or move the controls. Consult with the person that Use the Emergency Stop Button (if equipped)
attached the warning tag before the engine is ONLY in an emergency situation. Do not use the
started. Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
All protective guards and all protective covers must until the problem that caused the emergency stop
be installed if the engine must be started in order has been corrected.
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work Stop the engine if an overspeed condition occurs
around the parts carefully. during the initial start-up of a new engine or an
engine that has been overhauled. This may be
Start the engine from the operator’s compartment or accomplished by shutting off the fuel supply to
from the engine start switch. the engine and/or shutting off the air supply to the
engine.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation i01930348

Section. Knowing the correct procedure will help to Electrical System

prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
Never disconnect any charging unit circuit or battery
To ensure that the jacket water heater (if equipped) circuit cable from the battery when the charging unit
and/or the lube oil heater (if equipped) is working is operating. A spark can cause the combustible
properly, check the water temperature gauge gases that are produced by some batteries to ignite.
and the oil temperature gauge during the heater
operation.
12
Safety Section
Electrical System

To help prevent sparks from igniting combustible

gases that are produced by some batteries, the
negative “−” jump start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting
motor is not equipped with a negative “−” terminal,
connect the jump start cable to the engine block.

Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. See
the Operation and Maintenance Manual for specific
starting instructions.

Grounding Practices
Proper grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.

Uncontrolled electrical circuit paths can result in

damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frame

ground straps can be damaged by electrical
discharge.

To ensure that the engine and the engine electrical

systems function properly, an engine-to-frame
ground strap with a direct path to the battery must
be used. This path may be provided by way of a
direct engine ground to the frame.

All grounds should be tight and free of corrosion.

The engine alternator must be grounded to the
negative “-” battery terminal with a wire that is
adequate to handle the full charging current of the
alternator.
 13
Product Information Section
Model Views

Product Information
Section

Model Views
i01928892

Model View Illustrations

1104 Engine Model Views

g01012280
Illustration 7
(1) Valve mechanism cover (4) Fuel injection pump (7) Water pump
(2) Crankcase breather (5) Engine oil filter (8) Fan pulley
(3) Fuel filter (6) Crankshaft pulley (9) Water temperature regulator housing
14
Product Information Section
Model Views

g01012281
Illustration 8
(1) Oil filler cap (5) Starter motor
(2) Exhaust manifold (6) Flywheel housing
(3) Alternator (7) Flywheel
(4) Turbocharger (8) Air intake
 15
Product Information Section
Model Views

1103 Engine Model Views

g01011348
Illustration 9
(1) Alternator (3) Turbocharger oil supply (5) Turbocharger
(2) Fan pulley (4) Turbocharger oil drain (6) exhaust manifold
16
Product Information Section
Model Views

g01011349
Illustration 10
(1) Fuel transfer pump (6) Oil filter
(2) Oil filler cap (7) Oil pan
(3) Fuel filter (8) Crankshaft pulley
(4) Starter motor (9) Water pump
(5) Dipstick (10) Water temperature regulator housing

i01928893 • Naturally aspirated

Engine Description
Engine Specifications
Note: The front end of the engine is opposite the
The Perkins Industrial Engines are designed for flywheel end of the engine. The left and the right
the following applications: machine and industrial sides of the engine are determined from the flywheel
mobile equipment. The engines are available in the end. The number 1 cylinder is the front cylinder.
following types of aspiration:

• Turbocharged aftercooled
• Turbocharged
 17
Product Information Section
Model Views

Table 2
1103 Industrial Engine Specifications
Number of Cylinders 3 In-Line
Bore 105 mm (4.134 inch)
Stroke 127 mm (5.0 inch)
Aspiration Turbocharged
Naturally aspirated
Compression Ratio NA 19.2:1
T 18.25:1
Displacement 3.3 L (201 in3)
Firing Order 1 2 3
g00984281
Illustration 11
Rotation (flywheel end) Counterclockwise
A typical example of the layout of the valves
(A) Inlet valves Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
(B) Exhaust valves
Valve Lash Setting 0.45 mm (0.018 inch)
Table 1
(Exhaust)

1104 Industrial Engine Specifications

Number of Cylinders 4 In-Line Engine Cooling and Lubrication
Bore 105 mm (4.134 inch) The cooling system consists of the following
Stroke 127 mm (5.0 inch)
components:

Aspiration Turbocharged aftercooled • Gear-driven centrifugal water pump

Turbocharged
Naturally aspirated • Water temperature regulator which regulates the
Compression Ratio NA 19.3:1 NA engine coolant temperature
T 18.2:1 T, TA
• Gear-driven oil pump (gear type)
Displacement 4.4 L (268 in 3)
Firing Order 1 3 4 2 • Oil cooler
Rotation (flywheel end) Counterclockwise The engine lubricating oil is supplied by a gear
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) type pump. The engine lubricating oil is cooled
and the engine lubricating oil is filtered. Bypass
Valve Lash Setting valves provide unrestricted flow of lubrication oil
0.45 mm (0.018 inch)
(Exhaust) to the engine parts when oil viscosity is high.
Bypass valves can also provide unrestricted flow of
lubrication oil to the engine parts if the oil cooler
should become plugged or if the oil filter element
should become plugged.

Engine efficiency, efficiency of emission

controls, and engine performance depend on
adherence to proper operation and maintenance
recommendations. Engine performance and
efficiency also depend on the use of recommended
fuels, lubrication oils, and coolants. Refer to the
Operation and Maintenance Manual, “Maintenance
Interval Schedule” for more information on
maintenance items.
18
Product Information Section
Model Views

Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants and
lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.

Expected engine life is generally predicted

by the average power that is demanded. The
average power that is demanded is based on fuel
consumption of the engine over a period of time.
Reduced hours of operation at full throttle and/or
operating at reduced throttle settings result in a
lower average power demand. Reduced hours of
operation will increase the length of operating time
before an engine overhaul is required.
 19
Product Information Section
Product Identification Information

Product Identification The Serial Number Plate is located on the left side
of the cylinder block behind the high pressure pipes
Information of the Fuel injection pump.

The following information is stamped on the Serial

i01940475 Number Plate: Engine serial number, Model, and
Engine Identification Arrangement number.

i01892045

Perkins engines are identified by a serial number. Reference Numbers

This number is shown on a serial number plate that
is mounted on the left hand side of the engine block.

An example of an engine number is REU090001H. Information for the following items may be needed
to order parts. Locate the information for your
RE _________________________________________Type of engine engine. Record the information on the appropriate
space. Make a copy of this list for a record. Keep
U __________________________Built in the United Kingdom the information for future reference.

0900001 ________________________Engine Serial Number Record for Reference

H ____________________________________Year of Manufacture Engine Model ______________________________________________
Perkins dealers need these numbers in order to Engine Serial No. __________________________________________
determine the components that were included with
the engine. This permits accurate identification of Engine Low Idle rpm _____________________________________
replacement part numbers.
Engine Full Load rpm ____________________________________
i01940474
Primary Fuel Filter No. ___________________________________
Serial Number Plate
Water Separator Element No. __________________________

Secondary Fuel Filter Element No. ____________________

Lubrication Oil Filter Element No. _____________________

Auxiliary Oil Filter Element No. _________________________

Total Lubrication System Capacity ____________________

Total Cooling System Capacity ________________________

Air Cleaner Element No. _________________________________

Fan Drive Belt No. ________________________________________

Alternator Belt No. ________________________________________

i01925933

Emissions Certification Film

g00994966
Illustration 12
Typical serial number plate A typical example is shown.
(1) Temporary Parts List number
(2) Type
(3) Serial number
(4) List number
20
Product Information Section
Product Identification Information

g01002325
Illustration 13
 21
Operation Section
Lifting and Storage

Operation Section i01930351

Engine Storage
Lifting and Storage
If the engine will not be started for several weeks,
i01898037 the lubricating oil will drain from the cylinder walls
and from the piston rings. Rust can form on the
Engine Lifting cylinder walls. Rust on the cylinder walls will cause
increased engine wear and a reduction in engine
service life.

Lubrication System
To help prevent excessive engine wear, use the
following guidelines:

Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).

If an engine is out of operation and if use of the

engine is not planned, special precautions should
be made. If the engine will be stored for more than
Illustration 14 g00103219 one month, a complete protection procedure is
recommended.
NOTICE Use the following guidelines :
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
• Completely clean the outside of the engine.
between the supporting members and the object be-
comes less than 90 degrees.
• Drain the fuel system completely and refill
the system with preservative fuel.1772204
POWERPART Lay-Up 1 can be mixed with the
When it is necessary to remove a component at an normal fuel in order to change the fuel into
angle, only use a link bracket that is properly rated for preservative fuel.
the weight.
• If preservative fuel is not available, the fuel system
Use a hoist to remove heavy components. Use can be filled with normal fuel. This fuel must
an adjustable lifting beam to lift the engine. All be discarded at the end of the storage period
supporting members (chains and cables) should together with the fuel filter elements.
be parallel to each other. The chains and cables
should be perpendicular to the top of the object • Operate the engine until the engine reaches
that is being lifted. normal operating temperature. Stop any leaks
from fuel, lubricating oil or air systems. Stop the
Some removals require lifting the fixtures in order to engine and drain the lubricating oil from the oil
obtain proper balance and safety. pan.

To remove the engine ONLY, use the lifting eyes that • Renew the canister(s) of the lubricating oil filter.
are on the engine.

Lifting eyes are designed and installed for specific

engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Perkins dealer for information
regarding fixtures for proper engine lifting.
22
Operation Section
Lifting and Storage

• Fill the oil pan to the Full Mark on the dipstick 4. Open the tap or remove the drain plug at the
with new, clean lubricating oil. Add 1762811 bottom of the radiator in order to drain the
POWERPART Lay-Up 2 to the oil in order to radiator. If the radiator does not have a tap or a
protect the engine against corrosion. If 1762811 drain plug, disconnect the hose at the bottom
POWERPART Lay-Up 2 is not available, use a of the radiator.
preservative of the correct specification instead
of the lubricating oil. If a preservative is used, 5. Flush the cooling system with clean water.
this must be drained completely at the end of the
storage period and the oil pan must be refilled to 6. Fit the drain plugs and the filler cap. Close the
the correct level with normal lubricating oil. tap or connect the radiator hose.

7. Fill the cooling system with an approved

Cooling System antifreeze mixture because this gives protection
against corrosion. The maximum flow rate is 1 L
To help prevent excessive engine wear, use the
(0.2200 Imp gal) per minute in order to fill the
following guidelines:
system.

NOTICE Note: Certain corrosion inhibitors could cause

Do not drain the coolant while the engine is still hot and damage to some engine components. Contact the
the system is under pressure because dangerous hot Service Department of Perkins for advice.
coolant can be discharged.
8. Operate the engine for a short period in order
to circulate the lubricating oil and the coolant
If freezing temperatures are expected, check the
in the engine.
cooling system for adequate protection against
freezing. See this Operation and Maintenance
9. Disconnect the battery. Put the battery into safe
Manual, “General Coolant Information” (Maintenance
storage in a fully charged condition. Before the
Section).
battery is put into storage, protect the terminals
against corrosion.1734115 POWERPART Lay-Up
NOTICE 3 can be used on the terminals.
To prevent frost damage, ensure that all the coolant is
removed from the engine. This is important if the sys- 10. Clean the crankcase breather if one is installed.
tem is drained after it has been flushed with water, or if Seal the end of the pipe.
an antifreeze solution too weak to protect the system
from frost has been used. 11. Remove the fuel injector nozzles and spray
1762811 POWERPART Lay-Up 2 for one or two
seconds into each cylinder bore with the piston
at BDC.

12. Slowly rotate the crankshaft for one complete

revolution and then replace the fuel injector
nozzles.

Induction System
• Remove the air filter assembly. If necessary,
remove the pipes that are installed between
the air filter assembly and the turbocharger.
Spray 1762811 POWERPART Lay-Up 2 into the
g01003928 turbocharger. The duration of the spray is printed
Illustration 15
on the container. Seal the turbocharger with
waterproof tape.
1. Ensure that the vehicle is on level ground.

2. Remove the filler cap of the cooling system. Exhaust System

3. Remove the drain plug (1) from the side of the • Remove the exhaust pipe. Spray 1762811
cylinder block in order to drain the engine. POWERPART Lay-Up 2 into the turbocharger. The
Ensure that the drain hole is not restricted. duration of the spray is printed on the container.
Seal the turbocharger with waterproof tape.
 23
Operation Section
Lifting and Storage

General Items
• If the lubricating oil filler is installed on the rocker
cover, remove the filler cap. If the lubricating
oil filler cap is not installed on the rocker
cover, remove the rocker cover. Spray 1762811
POWERPART Lay-Up 2 around the rocker shaft
assembly. Replace the filler cap or the rocker
cover.

• Seal the vent of the fuel tank or the fuel filler cap
with waterproof tape.

• Remove the alternator drive belts and put the

drive belts into storage.

• In order to prevent corrosion, spray the engine

with 1734115 POWERPART Lay-Up 3. Do not
spray the area inside the alternator.

When the engine protection has been completed in

accordance with these instructions, this ensures that
no corrosion will occur. Perkins are not responsible
for damage which may occur when an engine is in
storage after a period in service.

Your Perkins dealer or your Perkins distributor can

assist in preparing the engine for extended storage
periods.
24
Operation Section
Gauges and Indicators

Gauges and Indicators 1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

i01930356
3. Determine if the engine must be shut down
Gauges and Indicators immediately or if the engine can be cooled by
reducing the load.

Tachometer – This gauge indicates engine

Your engine may not have the same gauges or all of speed (rpm). When the throttle control
the gauges that are described. For more information lever is moved to the full throttle position
about the gauge package, see the OEM information. without load, the engine is running at high idle. The
engine is running at the full load rpm when the
Gauges provide indications of engine performance. throttle control lever is at the full throttle position
Ensure that the gauges are in good working order. with maximum rated load.
Determine the normal operating range by observing
the gauges over a period of time.
NOTICE
Noticeable changes in gauge readings indicate To help prevent engine damage, never exceed the
potential gauge or engine problems. Problems may high idle rpm. Overspeeding can result in serious
also be indicated by gauge readings that change damage to the engine. The engine can be operated
even if the readings are within specifications. at high idle without damage, but should never be
Determine and correct the cause of any significant allowed to exceed high idle rpm.
change in the readings. Consult your Perkins dealer
or your Perkins distributor for assistance. Ammeter – This gauge indicates the
amount of charge or discharge in the
NOTICE battery charging circuit. Operation of the
If no oil pressure is indicated, STOP the engine. If indicator should be to the right side of “0”(zero).
maximum coolant temperature is exceeded, STOP the
engine. Engine damage can result. Fuel Level – This gauge indicates the fuel
level in the fuel tank. The fuel level gauge
Engine Oil Pressure – The oil pressure operates when the “START/STOP” switch
should be greatest after a cold engine is is in the “on” position.
started. The typical engine oil pressure
with SAE10W30 is 207 to 413 kPa (30 to 60 psi) at Service Hour Meter – The gauge indicates
rated rpm. operating time of the engine.

A lower oil pressure is normal at low idle. If the load

is stable and the gauge reading changes, perform
the following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature –

Typical temperature range is 71 to 96C
(160 to 205F). The maximum allowable
temperature with the pressurized cooling system at
48 kPa (7 psi) is 110C (230F). Higher temperatures
may occur under certain conditions. The water
temperature reading may vary according to load.
The reading should never exceed the boiling point
for the pressurized system that is being used.

If the engine is operating above the normal range

and steam becomes apparent, perform the following
procedure:
 25
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
i01903008 switch or to the controls.

Before Starting Engine • Ensure that the areas around the rotating parts
are clear.

• All of the guards must be put in place. Check for

Before the engine is started, perform the required damaged guards or for missing guards. Repair
daily maintenance and any other periodic any damaged guards. Replace damaged guards
maintenance that is due. Refer to the Operation and/or missing guards.
and Maintenance Manual, “Maintenance Interval
Schedule” for more information. • Disconnect any battery chargers that are not
protected against the high current drain that
• For the maximum service life of the engine, is created when the electric starting motor is
make a thorough inspection within the engine engaged. Check electrical cables and check the
compartment before the engine is started. Look battery for poor connections and for corrosion.
for the following items: oil leaks, coolant leaks,
loose bolts, and excessive dirt and/or grease. • Reset all of the shutoffs or alarm components (if
Remove any excess dirt and/or grease buildup. equipped).
Repair any faults that were identified during the
inspection. • Check the engine lubrication oil level. Maintain
the oil level between the “ADD” mark and the
• Inspect the cooling system hoses for cracks and “FULL” mark on the oil level dipstick.
for loose clamps.
• Check the coolant level. Observe the coolant
• Inspect the alternator and accessory drive belts level in the header tank (if equipped). Maintain
for cracks, breaks, and other damage. the coolant level to the “FULL” mark on the
header tank.
• Inspect the wiring for loose connections and for
worn wires or frayed wires. • If the engine is not equipped with a header tank
maintain the coolant level within 13 mm (0.5 inch)
• Check the fuel supply. Drain water from the water of the bottom of the filler pipe. If the engine is
separator (if equipped). Open the fuel supply equipped with a sight glass, maintain the coolant
valve (if equipped). level in the sight glass.

NOTICE • Observe the air cleaner service indicator (if

All valves in the fuel return line must be open before equipped). Service the air cleaner when the
and during engine operation to help prevent high fuel yellow diaphragm enters the red zone, or when
pressure. High fuel pressure may cause filter housing the red piston locks in the visible position.
failure or other damage.
• Ensure that any equipment that is driven by the
engine has been disengaged from the engine.
If the engine has not been started for several Minimize electrical loads or remove any electrical
weeks, fuel may have drained from the fuel system. loads.
Air may have entered the filter housing. Also, when
fuel filters have been changed, some air pockets
will be trapped in the engine. In these instances, i01762004
prime the fuel system. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime” for
Starting the Engine
more information on priming the fuel system.

Engine exhaust contains products of combustion Do not use aerosol types of starting aids such as
which may be harmful to your health. Always start ether. Such use could result in an explosion and
and operate the engine in a well ventilated area personal injury.
and, if in an enclosed area, vent the exhaust to the
outside.
26
Operation Section
Engine Starting

Refer to the Service Manual for your type of controls. i01928991

Use the following procedure to start the engine.
Cold Weather Starting
1. Move the throttle lever to the full throttle position
before you start the engine.

NOTICE
Do not operate the glow plugs for more than 60 sec-
onds at one time. Damage to the glow plugs could oc- Do not use aerosol types of starting aids such as
cur. ether. Such use could result in an explosion and
personal injury.
2. Turn the engine start switch to the HEAT position.
Hold the engine start switch in the HEAT position Startability will be improved at temperatures below
for 6 seconds until the glow plug indicator light −18 C (0 F) from the use of a jacket water heater
illuminates. This will activate the glow plugs and or extra battery capacity.
aid in the starting of the engine.
When Group 2 diesel fuel is used, the following
items provide a means of minimizing starting
NOTICE
Do not crank the engine for more than 30 seconds. problems and fuel problems in cold weather: engine
Allow the electric starting motor to cool for two minutes oil pan heaters, jacket water heaters, fuel heaters,
and fuel line insulation.
before cranking the engine again.
Use the procedure that follows for cold weather
3. While the glow plug indicator light is illuminated, starting.
turn the engine start switch to the START position
and crank the engine. 1. The governor control needs to be in the LOW
IDLE position if the temperature is below 0 C
4. When the engine starts, release the engine start (32 F).
switch.
2. Activate the glow plugs for 6 seconds.
5. Slowly move the throttle lever to the low idle
position and allow the engine to idle. Refer to NOTICE
the Operation and Maintenance Manual, “After Do not crank the engine for more than 30 seconds.
Starting Engine” topic. Allow the electric starting motor to cool for two minutes
before cranking the engine again.
Note: If the glow plug indicator light illuminates
rapidly for 2 to 3 seconds, or if the glow plug
indicator light fails to illuminate, a malfunction exists 3. Turn the engine start switch to the START
in the cold start system. Do not use ether or other position.
starting fluids to start the engine.
4. When the engine starts, release the engine start
6. If the engine does not start, release the engine switch key.
start switch and allow the electric starting motor
to cool. Then, repeat steps 2 through step 5. 5. If the engine does not start, release the engine
start switch and allow the starter motor to cool.
7. Turn the engine start switch to the OFF position Then, repeat steps 2 through step 4.
in order to stop the engine.
6. Allow the engine to idle for three to five minutes,
or allow the engine to idle until the water
temperature indicator begins to rise. The engine
should run at low idle smoothly until speed
is gradually increased to high idle. Allow the
white smoke to disperse before proceeding with
normal operation.

7. Operate the engine at low load until all systems

reach operating temperature. Check the gauges
during the warm-up period.
 27
Operation Section
Engine Starting

i01929012 3. Connect one negative end of the jump start cable

to the negative cable terminal of the electrical
Starting with Jump Start source. Connect the other negative end of the
Cables jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting the combustible
gases that are produced by some batteries.

4. Start the engine.

Improper jump start cable connections can cause 5. Immediately after the stalled engine is started,
an explosion resulting in personal injury. disconnect the jump start cables in reverse order.
Prevent sparks near the batteries. Sparks could After jump starting, the alternator may not be
cause vapors to explode. Do not allow jump start able to fully recharge batteries that are severely
cable ends to contact each other or the engine. discharged. The batteries must be replaced or
charged to the proper voltage with a battery charger
Note: If it is possible, first diagnose the reason after the engine is stopped. Many batteries which
for the starting failure. Make any necessary are considered unusable are still rechargeable.
repairs. If the engine will not start only due to Refer to Operation and Maintenance Manual,
the condition of the battery, either charge the “Battery - Replace” and Testing and Adjusting
battery, or start the engine with jump start cables. Manual, “Battery - Test”.
The condition of the battery can be rechecked
after the engine has been switched OFF. i01903609

After Starting Engine

NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage Note: In temperatures from 0 to 60C (32 to 140F),
the electrical system. the warm-up time is approximately three minutes. In
temperatures below 0C (32F), additional warm-up
Do not reverse the battery cables. The alternator can time may be required.
be damaged. Attach ground cable last and remove
first. When the engine idles during warm-up, observe
the following conditions:
When using an external electrical source to start the
engine, turn the engine control switch to the “OFF” po- • Check for any fluid or for any air leaks at idle rpm
sition. Turn all electrical accessories OFF before at- and at one-half full rpm (no load on the engine)
taching the jump start cables. before operating the engine under load. This is
not possible in some applications.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en- • Operate the engine at low idle until all systems
gine being started. achieve operating temperatures. Check all
gauges during the warm-up period.
1. Turn the start switch to the OFF position. Turn off Note: Gauge readings should be observed and the
all the engine’s accessories. data should be recorded frequently while the engine
is operating. Comparing the data over time will
2. Connect one positive end of the jump start cable help to determine normal readings for each gauge.
to the positive cable terminal of the discharged Comparing data over time will also help detect
battery. Connect the other positive end of the abnormal operating developments. Significant
jump start cable to the positive cable terminal changes in the readings should be investigated.
of the electrical source.
28
Operation Section
Engine Operation

Engine Operation i01929465

Fuel Conservation Practices

i01903587

Engine Operation
The efficiency of the engine can affect the fuel
economy. Perkins’ design and technology in
manufacturing provides maximum fuel efficiency
Proper operation and maintenance are key factors in all applications. Follow the recommended
in obtaining the maximum life and economy of procedures in order to attain optimum performance
the engine. If the directions in the Operation and for the life of the engine.
Maintenance Manual are followed, costs can
be minimized and engine service life can be • Avoid spilling fuel.
maximized.
Fuel expands when the fuel is warmed up. The fuel
The engine can be operated at the rated rpm after may overflow from the fuel tank. Inspect fuel lines
the engine reaches operating temperature. The for leaks. Repair the fuel lines, as needed.
engine will reach normal operating temperature
sooner during a low engine speed (rpm) and • Be aware of the properties of the different fuels.
during a low power demand. This procedure is Use only the recommended fuels.
more effective than idling the engine at no load.
The engine should reach operating temperature in • Avoid unnecessary idling.
a few minutes.
Shut off the engine rather than idle for long periods
Gauge readings should be observed and the data of time.
should be recorded frequently while the engine is
operating. Comparing the data over time will help • Observe the service indicator frequently. Keep
to determine normal readings for each gauge. the air cleaner elements clean.
Comparing data over time will also help detect
abnormal operating developments. Significant • Maintain a good electrical system.
changes in the readings should be investigated.
One bad battery cell will overwork the alternator.
This will consume excess power and excess fuel.
i01929404

Engine Warm-up • Ensure that the belts are properly adjusted. The
belts should be in good condition.

• Ensure that all of the connections of the hoses

are tight. The connections should not leak.
1. Run the engine at low idle for three to five
minutes, or run the engine at low idle until the
jacket water temperature starts to rise. • Ensure that the driven equipment is in good
working order.
More time may be necessary when the
temperature is below −18C (0F). • Cold engines consume excess fuel. Utilize heat
from the jacket water system and the exhaust
system, when possible. Keep cooling system
2. Check all of the gauges during the warm-up
components clean and keep cooling system
period.
components in good repair. Never operate the
engine without water temperature regulators.
3. Perform a walk-around inspection. Check the
All of these items will help maintain operating
engine for fluid leaks and air leaks.
temperatures.
4. Increase the rpm to the rated rpm. Check for
fluid leaks and air leaks. The engine may be
operated at full rated rpm and at full load when
the temperature of the water jacket reaches 60C
(140F).
 29
Operation Section
Engine Stopping

Engine Stopping i01903608

After Stopping Engine

i01929389

Stopping the Engine

Note: Before you check the engine oil, do not
operate the engine for at least 10 minutes in order
to allow the engine oil to return to the oil pan.
NOTICE
Stopping the engine immediately after it has been • Check the crankcase oil level. Maintain the oil
level between the “ADD” mark and the “FULL”
working under load can result in overheating and ac-
mark on the oil level dipstick.
celerated wear of the engine components.

If the engine has been operating at high rpm and/or • If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.
high loads, run at low idle for at least three minutes
to reduce and stabilize internal engine temperature
before stopping the engine. • Note the required service interval. Perform
the maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Avoiding hot engine shutdowns will maximize tur-
Schedule”.
bocharger shaft and bearing life.
• Fill the fuel tank in order to help prevent
Prior to stopping an engine that is being operated accumulation of moisture in the fuel. Do not
at low loads, operate the engine at low idle for 30 overfill the fuel tank.
seconds before stopping. If the engine has been
operating at highway speeds and/or at high loads, NOTICE
operate the engine at low idle for at least three Only use antifreeze/coolant mixtures recommended in
minutes. This procedure will cause the internal the Coolant Specifications that are in the Operation
engine temperature to be reduced and stabilized. and Maintenance Manual. Failure to do so can cause
engine damage.
Ensure that the engine stopping procedure is
understood. Stop the engine according to the
shutoff system on the engine or refer to the • Allow the engine to cool. Check the coolant level.
instructions that are provided by the OEM.
• If freezing temperatures are expected, check the
• To stop the engine, turn the ignition key switch to coolant for the correct antifreeze protection. The
the OFF position. cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the correct coolant/water mixture, if necessary.
i01903586

Emergency Stopping • Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
the instructions from the OEM.

NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.

The OEM may have equipped the application with

an emergency stop button. For more information
about the emergency stop button, refer to the OEM
information.

Ensure that any components for the external system

that support the engine operation are secured after
the engine is stopped.
30
Operation Section
Cold Weather Operation

Cold Weather Operation • Install the correct lubricant in each compartment

before the beginning of cold weather.

i01930355 • Check all rubber parts (hoses, fan drive belts,

etc) weekly.
Cold Weather Operation
• Check all electrical wiring and connections for
any fraying or damaged insulation.

Perkins Diesel Engines can operate effectively in • Keep all batteries fully charged and warm.
cold weather. During cold weather, the starting and
the operation of the diesel engine is dependent on • Fill the fuel tank at the end of each shift.
the following items:
• Check the air cleaners and the air intake daily.
• The type of fuel that is used Check the air intake more often when you operate
in snow.
• The viscosity of the oil
• The operation of the glow plugs
Personal injury or property damage can result
• Optional Cold starting aid from alcohol or starting fluids.
The purpose of this section will cover the following
information: Alcohol or starting fluids are highly flammable and
toxic and if improperly stored could result in injury
or property damage.
• Explain potential problems that are caused by
cold weather operation.

• Suggest steps which can be taken in order

to minimize starting problems and operating
Do not use aerosol types of starting aids such as
problems when the ambient air temperature is
ether. Such use could result in an explosion and
colder than 0 to −55 C (32 to −67 F).
personal injury.
The operation and maintenance of an engine in
freezing temperatures is complex. This is because • For jump starting with cables in cold weather,
of the following conditions: The unlimited differences refer to the Operation and Maintenance Manual,
in weather conditions, engine applications, and “Starting with Jump Start Cables.” for instructions.
the supplies that are available in your area. These
factors and recommendations from your Perkins
dealer are based on past proven practices. The
Viscosity of the Engine Lubrication
information that is contained in this section should Oil
be combined in order to provide guidelines for cold
weather operations. Proper engine oil viscosity is essential. Oil viscosity
affects the amount of torque that is needed to
crank the engine. Refer to the Operation and
Hints for Cold Weather Operation Maintenance Manual, “Lubricant Specifications” for
the recommended viscosity of oil.
• If the engine will start, operate the engine

until a

minimum operating temperature of 71 C (160 F)
is achieved. Achieving operating temperature will Recommendations for the Coolant
help prevent the intake valves and exhaust valves
from sticking. Provide cooling system protection for the lowest
expected outside temperature. Refer to the
• The cooling system and the lubrication system for Operation and Maintenance Manual, “General
the engine do not lose heat immediately upon Coolant Information” for the recommended coolant
shutdown. This means that an engine can be shut mixture.
down for a few hours and the engine can still have
the ability to start readily. If the engine is shut In cold weather, check the coolant often for the
down for at least eight hours, the engine should proper glycol concentration in order to ensure
be considered cooled to outside temperature. adequate freeze protection.
 31
Operation Section
Cold Weather Operation

Engine Block Heaters • Valves become stuck.

Engine block heaters (if equipped) heat the • Pushrods are bent.
engine jacket water that surrounds the combustion
chambers. This provides the following functions: • Other damage to valve train components can
result.
• Startability is improved.
For this reason, when the engine is started,
• Warm up time is reduced. the engine must be operated until the coolant
temperature is 71 C (160 F) minimum. Carbon
An electric block heater can be activated once deposits on the valve stems will be kept at a
the engine is stopped. An effective block heater minimum and the free operation of the valves and
is typically a 1250/1500 W unit. Consult your the valve components will be maintained.
Perkins dealer or your Perkins distributor for more
information. In addition, the engine must be thoroughly warmed
in order to keep other engine parts in better
condition and the service life of the engine will be
Idling the Engine generally extended. Lubrication will be improved.
When idling after the engine is started in cold There will be less acid and less sludge in the oil.
This will provide longer service life for the engine
weather, increase the engine rpm from 1000 to 1200
bearings, the piston rings, and other parts. However,
rpm. This will warm up the engine more quickly.
Maintaining an elevated low idle speed for extended limit unnecessary idle time to ten minutes in order
to reduce wear and unnecessary fuel consumption.
periods will be easier with the installation of a hand
throttle. The engine should not be “raced” in order
to speed up the warm up process. Purge Valve and Insulated Heater Lines
While the engine is idling, the application of a light The engine is equipped with a water temperature
load (parasitic load) will assist in maintaining the regulator in order to allow the engine to reach the
minimum operating temperature. The minimum correct operating temperature quickly. The water
operating temperature is 71 C (160 F). temperature regulator remains in the closed position
until the jacket water coolant temperature has
reached the engine’s operating temperature. The
Recommendations for Coolant jacket water circulates from the top of the cylinder
Warm Up block, to the water temperature regulator housing,
and back to the bottom of the cylinder block via
Warm up an engine that has cooled below normal the bypass. The water temperature regulator allows
operating temperatures due to inactivity. This should some flow of water and/or air to pass through the
be performed before the engine is returned to full water temperature regulator in order to ensure a
operation. During operation in very cold temperature continuous flow of coolant within the cylinder block.
conditions, damage to engine valve mechanisms This is achieved via a small “jiggle” valve in the
can result from engine operation for short intervals. water temperature regulator. The water temperature
This can happen if the engine is started and regulator moves to the open position when the
the engine is stopped many times without being jacket water coolant temperature has reached
operated in order to warm up completely. the correct operating temperature. The water
temperature regulator moves to the open position in
When the engine is operated below normal order to allow the passage of the coolant through
operating temperatures, fuel and oil are not the radiator to dissipate excess heat.
completely burned in the combustion chamber.
This fuel and oil causes soft carbon deposits to The above procedure is good for normal engine
form on the valve stems. Generally, the deposits do operating conditions in temperate climates. During
not cause problems and the deposits are burned periods of operations in a cold climate with a light
off during operation at normal engine operating engine load, the coolant must bypass the radiator
temperatures. in order to help prevent excessive cooling of the
engine. Coolant that passes through the radiator
When the engine is started and the engine is must be minimized in order to maintain the engine
stopped many times without being operated in operating temperature in cold weather.
order to warm up completely, the carbon deposits
become thicker. This will cause the following
problems:

• Free operation of the valves is prevented.

32
Operation Section
Cold Weather Operation

Excessive cooling of the engine can be prevented Note: Group 3 fuels reduce the life of the engine.
by a valve that allows unnecessary coolant flow to The use of Group 3 fuels is not covered by the
be diverted from the water temperature regulator Perkins warranty.
and back to the bottom of the engine block without
passing through the radiator. Special fuels include Biofuel.

Note: Perkins discourages the use of all airflow Group 1 fuels are the preferred Group of Fuels for
restriction devices such as radiator shutters. general use by Perkins. Group 1 fuels maximize
Restriction of the airflow can result in the following: engine life and engine performance. Group 1
High exhaust temperatures, power loss, excessive fuels are usually less available than Group 2 fuels.
fan usage, and reduction in fuel economy. Frequently, Group 1 fuels are not available in colder
climates during the winter.
Cab heater lines for very cold weather are also
beneficial. These lines provide more available heat Note: Group 2 fuels must have a maximum wear
from the coolant to the cab. The feed from the scar of 650 micrometers (HFRR to ISO 12156-1).
engine and the return lines from the cab should be
insulated in order to reduce heat loss to the outside Group 2 fuels are considered acceptable for issues
air. of warranty. This group of fuels may reduce the life
of the engine, the engine’s maximum power, and
Insulating the Air Inlet and Engine the engine’s fuel efficiency.
Compartment When Group 2 diesel fuels are used the following
  components provide a means of minimizing
When temperatures below −18 C (−0 F) will be problems in cold weather:
frequently encountered, an air cleaner inlet that
is located in the engine compartment may be
specified. An air cleaner that is located in the • Glow plugs, which are standard equipment on
all engines
engine compartment may also minimize the entry of
snow into the air cleaner. Also, heat that is rejected
by the engine helps to warm the intake air. • Engine coolant heaters, which may be an OEM
option
Additional heat can be retained around the engine
by insulating the engine compartment. • Fuel heaters, which may be an OEM option
• Fuel line insulation, which may be an OEM option
i01930354
There are three major differences between Group
Fuel and the Effect from Cold 1 fuels and Group 2 fuels. Group 1 fuels have the
following different characteristics to Group 2 fuels.
Weather
• A lower cloud point

Note: Only use grades of fuel that are recommended • A lower pour point
by Perkins. Refer to this Operation and Maintenance
Manual, “Fuel Recommendations”. • A higher rating of kJ (BTU) per unit volume of fuel
The cloud point is the temperature when a cloud
The following fuels can be used for the Perkins
of wax crystals begins to form in the fuel. These
engines.
crystals can cause the fuel filters to plug. The
pour point is the temperature when diesel fuel will
• Group 1 thicken. The diesel fuel becomes more resistant to
flow through fuel pumps and through the fuel lines.
• Group 2
Be aware of these values when diesel fuel is
• Group 3 purchased. Consider the average ambient air
temperature for the engine’s application. Engines
• Special Fuels that are fueled in one climate may not operate well if
the engines are moved to another climate. Problems
Perkins prefer only Group 1 and Group 2 fuels for
can result due to changes in temperature.
use in Perkins engines. Group 3 fuels include Low
Temperature Fuels and Aviation Kerosene Fuels.
 33
Operation Section
Cold Weather Operation

Before troubleshooting for low power or for poor i01903588

performance in the winter, check the type of fuel
that is being used. Fuel Related Components in
Low temperature fuels may be available for engine
Cold Weather
operation at temperatures below 0 C (32 F). These
fuels limit the formation of wax in the fuel at low
temperatures. Wax in the fuel may prevent the flow
of the fuel through the fuel filters. Fuel Tanks
For more information on cold weather operation, Condensation can form in partially filled fuel tanks.
see Operation and Maintenance Manual, “Cold Top off the fuel tanks after you operate the engine.
Weather Operation and Fuel Related Components
in Cold Weather”. Fuel tanks should contain some provision for
draining water and sediment from the bottom of the
tanks. Some fuel tanks use supply pipes that allow
water and sediment to settle below the end of the
fuel supply pipe.

Some fuel tanks use supply lines that take fuel

directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.

Drain the water and sediment from any fuel storage

tank at the following intervals: weekly, oil changes,
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.

Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more
information on priming the fuel system.

The micron rating and the location of a primary

fuel filter is important in cold weather operation.
The primary fuel filter and the fuel supply line are
the most common components that are affected by
cold fuel.

Fuel Heaters
Note: The OEM may equip the application with fuel
heaters. If this is the case, disconnect an electric
type of fuel heater in warm weather in order to
prevent overheating of the fuel. If the type of fuel
heater is a heat exchanger, the OEM should have
included a bypass for warm weather. Ensure that
the bypass is operational during warm weather in
order to prevent overheating of the fuel.

For more information about fuel heaters (if

equipped), refer to the OEM information.
34
Maintenance Section
Lubricant Specifications

Maintenance Section Table 3

API Classifications
Current Obsolete
Lubricant Specifications CF-4, CG-4, CH-4 CE
CF CC, CD
i01903582
CF-2(1) CD-2(1)
Lubricant Information (1) The classifications CD-2 and American Petroleum Institute
CF-2 are for two-cycle diesel engines. Perkins does not sell
engines that utilize CD-2 and API CF-2 oils.

General Information Terminology

Because of government regulations regarding Certain abbreviations follow the nomenclature of

the certification of engine exhaust emissions, the “SAE J754”. Some classifications follow “SAE J183”
lubricant recommendations must be followed. abbreviations, and some classifications follow
the “EMA Recommended Guideline on Diesel
Engine Oil”. In addition to Perkins definitions, there
Engine Manufacturers Association are other definitions that will be of assistance in
(EMA) Oils purchasing lubricants. Recommended oil viscosities
can be found in this publication, “Engine Oil” topic
The “Engine Manufacturers Association (Maintenance Section).
Recommended Guideline on Diesel Engine Oil” is
recognized by Perkins. For detailed information i01903583
about this guideline, see the latest edition of EMA
publication, “EMA DHD -1”. Engine Oil
API Oils
The Engine Oil Licensing and Certification System Commercial Oils
by the American Petroleum Institute (API) is
recognized by Perkins. For detailed information The performance of commercial diesel engine
about this system, see the latest edition of the “API oils is based on American Petroleum Institute
publication No. 1509”. Engine oils that bear the API (API) classifications. These API classifications are
symbol are authorized by API. developed in order to provide commercial lubricants
for a broad range of diesel engines that operate at
various conditions.

Only use commercial oils that meet the following

classifications:

• EMA DHD-1 multigrade oil (preferred oil)

• API CH-4 multigrade oil (preferred oil)
• ACEAE3
In order to make the proper choice of a commercial
oil, refer to the following explanations:
g00546535
Illustration 16
Typical API symbol

Diesel engine oils CC, CD, CD-2, and CE have

not been API authorized classifications since 1
January 1996. Table 3 summarizes the status of the
classifications.
 35
Maintenance Section
Lubricant Specifications

EMA DHD-1 – The Engine Manufacturers Three new engine tests were developed for the
Association (EMA) has developed lubricant API CH-4 oil. The first test specifically evaluates
recommendations as an alternative to the API oil deposits on pistons for engines with the two-piece
classification system. DHD-1 is a Recommended steel piston. This test (piston deposit) also measures
Guideline that defines a level of oil performance the control of oil consumption. A second test is
for these types of diesel engines: high speed, four conducted with moderate oil soot. The second
stroke cycle, heavy-duty, and light duty. DHD-1 oils test measures the following criteria: wear of piston
may be used in Perkins engines when the following rings, wear of cylinder liners, and resistance to
oils are recommended: API CH-4, API CG-4, and corrosion. A third new test measures the following
API CF-4. DHD-1 oils are intended to provide characteristics with high levels of soot in the oil:
superior performance in comparison to API CG-4 wear of the valve train, resistance of the oil in
and API CF-4. plugging the oil filter, and control of sludge.

DHD-1 oils will meet the needs of high performance In addition to the new tests, API CH-4 oils have
Perkins diesel engines that are operating in many tougher limits for viscosity control in applications
applications. The tests and the test limits that that generate high soot. The oils also have improved
are used to define DHD-1 are similar to the new oxidation resistance. API CH-4 oils must pass an
API CH-4 classification. Therefore, these oils will additional test (piston deposit) for engines that use
also meet the requirements of the low emissions aluminum pistons (single piece). Oil performance is
diesel engines. DHD-1 oils are designed to control also established for engines that operate in areas
the harmful effects of soot with improved wear with high sulfur diesel fuel.
resistance and improved resistance to plugging of
the oil filter. These oils will also provide superior All of these improvements allow the API CH-4 oil to
piston deposit control for engines with either achieve optimum oil change intervals. API CH-4 oils
two-piece steel pistons or aluminum pistons. are recommended for use in extended oil change
intervals. API CH-4 oils are recommended for
All DHD-1 oils must complete a full test program conditions that demand a premium oil. Your Perkins
with the base stock and with the viscosity grade of dealer or your Perkins distributor has specific
the finished commercial oil. The use of “API Base guidelines for optimizing oil change intervals.
Oil Interchange Guidelines” are not appropriate for
DHD-1 oils. This feature reduces the variation in Some commercial oils that meet the API
performance that can occur when base stocks are classifications may require reduced oil change
changed in commercial oil formulations. intervals. To determine the oil change interval,
closely monitor the condition of the oil and perform
DHD-1 oils are recommended for use in extended a wear metal analysis.
oil change interval programs that optimize oil life.
These oil change interval programs are based NOTICE
on oil analysis. DHD-1 oils are recommended for Failure to follow these oil recommendations can cause
conditions that demand a premium oil. Your Perkins shortened engine service life due to deposits and/or
dealer or your Perkins distributor has the specific excessive wear.
guidelines for optimizing oil change intervals.

API CH-4 – API CH-4 oils were developed in Total Base Number (TBN) and Fuel
order to meet the requirements of the new high
performance diesel engines. Also, the oil was Sulfur Levels for Direct Injection
designed to meet the requirements of the low (DI) Diesel Engines
emissions diesel engines. API CH-4 oils are also
acceptable for use in older diesel engines and The Total Base Number (TBN) for an oil depends on
in diesel engines that use high sulfur diesel fuel. the fuel sulfur level. For direct injection engines that
API CH-4 oils may be used in Perkins engines that use distillate fuel, the minimum TBN of the new oil
use API CG-4 and API CF-4 oils. API CH-4 oils will must be 10 times the fuel sulfur level. The TBN is
generally exceed the performance of API CG-4 oils defined by “ASTM D2896”. The minimum TBN of
in the following criteria: deposits on pistons, control the oil is 5 regardless of fuel sulfur level. Illustration
of oil consumption, wear of piston rings, valve train 17 demonstrates the TBN.
wear, viscosity control, and corrosion.
36
Maintenance Section
Lubricant Specifications

Refer to Table 5 (minimum temperature) in order

to determine the required oil viscosity for starting
a cold engine.

Refer to Table 5 (maximum temperature) in order to

select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that

is available to meet the requirement for the
temperature at start-up.
Table 5
Engine Oil Viscosity
g00799818
Illustration 17 EMA LRG-1 Ambient Temperature
(Y) TBN by “ASTM D2896” API CH-4
(X) Percentage of fuel sulfur by weight Viscosity Grade Minimum Maximum
(1) TBN of new oil  
(2) Change the oil when the TBN deteriorates to 50 percent of SAE 0W20 −40 C (−40 F) 10 C (50 F)
the original TBN.
SAE 0W30 −40 C (−40 F) 30 C (86 F)
Use the following guidelines for fuel sulfur levels SAE 0W40 −40 C (−40 F) 40 C (104 F)
that exceed 1.5 percent:
SAE 5W30 −30 C (−22 F) 30 C (86 F)
• Choose an oil with the highest TBN that meets SAE 5W40 −30 C (−22 F) 40 C (104 F)
one of these classifications: EMA DHD-1 and API
CH-4. SAE 10W30 −20 C (−4 F) 40 C (104 F)
SAE 15W40 −10 C (14 F) 50 C (122 F)
• Reduce the oil change interval. Base the oil
change interval on the oil analysis. Ensure that
the oil analysis includes the condition of the oil i01903738
and a wear metal analysis.
Synthetic Base Stock Oils
Excessive piston deposits can be produced by an
oil with a high TBN. These deposits can lead to a
loss of control of the oil consumption and to the
polishing of the cylinder bore. Synthetic base oils are acceptable for use in
these engines if these oils meet the performance
NOTICE requirements that are specified for the engine.
Operating Direct Injection (DI) diesel engines with fuel
sulphur levels over 0.5 percent will require shortened Synthetic base oils generally perform better than
oil change intervals in order to help maintain adequate conventional oils in the following two areas:
wear protection.
• Synthetic base oils have improved flow at low
temperatures especially in arctic conditions.
Table 4
Percentage of Sulfur in the Oil change interval • Synthetic base oils have improved oxidation
fuel stability especially at high operating temperatures.
Lower than 0.5 Normal Some synthetic base oils have performance
0.5 to 1.0 0.75 of normal characteristics that enhance the service life of the
oil. Perkins does not recommend the automatic
Greater than 1.0 0.50 of normal extending of the oil change intervals for any type
of oil.
Lubricant Viscosity Recommendations
for Direct Injection (DI) Diesel Engines
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during
cold engine start-up, and the maximum ambient
temperature during engine operation.
 37
Maintenance Section
Lubricant Specifications

i01903742
NOTICE
Re-refined Base Stock Oils Shortened engine service life could result if second
choice oils are used.

Re-refined base stock oils are acceptable for

i01904027
use in Perkins engines if these oils meet the
performance requirements that are specified by Aftermarket Oil Additives
Perkins. Re-refined base stock oils can be used
exclusively in finished oil or in a combination with
new base stock oils. The US military specifications
and the specifications of other heavy equipment Perkins does not recommend the use of aftermarket
manufacturers also allow the use of re-refined base additives in oil. It is not necessary to use aftermarket
stock oils that meet the same criteria. additives in order to achieve the engine’s maximum
service life or rated performance. Fully formulated,
The process that is used to make re-refined base finished oils consist of base oils and of commercial
stock oil should adequately remove all wear metals additive packages. These additive packages are
that are in the used oil and all the additives that blended into the base oils at precise percentages in
are in the used oil. The process that is used to order to help provide finished oils with performance
make re-refined base stock oil generally involves characteristics that meet industry standards.
the process of vacuum distillation and hydrotreating
the used oil. Filtering is adequate for the production There are no industry standard tests that evaluate
of high quality, re-refined base stock oil. the performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may
i01903752
not be compatible with the finished oil’s additive
package, which could lower the performance of the
Cold Weather Lubricants finished oil. The aftermarket additive could fail to
mix with the finished oil. This could produce sludge
in the crankcase. Perkins discourages the use of
aftermarket additives in finished oils.
When an engine is started and an engine is
operated in ambient temperatures below −20 C To achieve the best performance from a Perkins
(−4 F), use multigrade oils that are capable of engine, conform to the following guidelines:
flowing in low temperatures.
• Select the proper oil, or a commercial oil that
These oils have lubricant viscosity grades of SAE meets the “EMA Recommended Guideline on
0W or SAE 5W. Diesel Engine Oil” or the recommended API
classification.
When an engine is started and operated in ambient
temperatures below −30 C (−22 F), use a synthetic • See the appropriate “Lubricant Viscosities” table
base stock multigrade oil with a 0W viscosity grade in order to find the correct oil viscosity grade for
or with a 5W viscosity grade. Use an oil with a pour your engine.
point that is lower than −50 C (−58 F).
• At the specified interval, service the engine. Use
The number of acceptable lubricants is limited new oil and install a new oil filter.
in cold weather conditions. Perkins recommends
the following lubricants for use in cold weather • Perform maintenance at the intervals that are
conditions: specified in the Operation and Maintenance
Manual, “Maintenance Interval Schedule”.
First Choice – Use oil with an EMA DHD-1
Recommended Guideline. Use a CH-4 oil that has
an API license. The oil should be either SAE 0W20,
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
lubricant viscosity grade.

Second Choice – Use an oil that has a CH-4

additive package. Although the oil has not been
tested for the requirements of the API license, the oil
must be either SAE 0W20, SAE 0W30, SAE 0W40,
SAE 5W30, or SAE 5W40.
38
Maintenance Section
Lubricant Specifications

i01930352

S·O·S Oil Analysis

Some engines may be equipped with an oil

sampling valve. If S·O·S oil analysis is required the
oil sampling valve is used to obtain samples of the
engine oil. The S·O·S oil analysis will complement
the preventive maintenance program.

The S·O·S oil analysis is a diagnostic tool that is

used to determine oil performance and component
wear rates. Contamination can be identified and
measured through the use of the S·O·S oil analysis.
The S·O·S oil analysis includes the following tests:

• The Wear Rate Analysis monitors the wear of the

engine’s metals. The amount of wear metal and
type of wear metal that is in the oil is analyzed.
The increase in the rate of engine wear metal in
the oil is as important as the quantity of engine
wear metal in the oil.

• Tests are conducted in order to detect

contamination of the oil by water, glycol or fuel.

• The Oil Condition Analysis determines the loss

of the oil’s lubricating properties. An infrared
analysis is used to compare the properties of
new oil to the properties of the used oil sample.
This analysis allows technicians to determine
the amount of deterioration of the oil during use.
This analysis also allows technicians to verify
the performance of the oil according to the
specification during the entire oil change interval.
 39
Maintenance Section
Fuel Specifications

Fuel Specifications Diesel engines have the ability to burn a wide

variety of fuels. These fuels are divided into four
general groups:
i01904061
• Group 1 (preferred fuels)
Fuel Recommendations
• Group 2 (permissible fuels)
• Group 3 (aviation kerosene fuels)
To get the correct power and performance from
the engine, use a fuel of the correct quality. The • Other fuels
recommended fuel specification for the Perkins
1106 engine is shown below: Group 1 (preferred fuels): Specification

• Cetane number__________________________45 minimum “DERV to EN590”

• Viscosity___________2,0 to 4.5 cSt at 40 C (104 F) Note: Only use Arctic fuels when the temperature is
below 0 C (32 F). Do not use Arctic fuels when
• Density________________________0.835 to 0.855 Kg/liter the ambient temperature is above 0 C (32 F).
To ensure that the time period between cranking
• Sulfur_______________________0.2% of mass, maximum the engine and first fire is kept to a minimum, only
use fuel of the correct viscosity and at the correct
• Distillation___________________85% at 350 C (662 F) temperature.

• Lubricity______________________________460 micrometers Gas oil to “BS2869 Class A2”

maximum wear scar on “ISO 12156 - 1”
“ASTM D975 - 91 Class 2D” This can only be used
Cetane number if the fuel has the correct specification of lubricity.

This indicates the properties of ignition of the fuel. “JIS K2204 (1992) Grades 1,2,3 and Special Grade
Fuel with a low cetane number can be the root 3” This can only be used if the fuel has the correct
cause of problems during cold start. This will affect specification of lubricity.
combustion.
Note: If low sulfur or low sulfur aromatic fuels are
Viscosity used, then fuel additives can be used to increase
lubricity.
This is the resistance to flow of a fluid. If this
resistance is outside the limits, the engine and the Group 2 (permissible fuels): Specification
engine starting performance in particular can be
affected. These fuel specifications are considered acceptable
for issues of warranty. However,these fuels may
Sulfur reduce the life of the engine, the engine’s maximum
power and the engine’s fuel efficiency.
High sulfur content of the fuel is not normally found
in Europe, North America or Australasia. This can “ASTM D975 - 91 Class 1D”
cause engine wear. When only high sulfur fuels are
available, it will be necessary that high alkaline “JP7, Mil T38219”
lubricating oil is used in the engine or that the
lubricating oil change interval is reduced. “NATO F63”

Distillation NOTICE
These fuels should have a wear scar value of 650
This is an indication of the mixture of different micrometers maximum “HFRR to ISO 12156 - 1” and
hydrocarbons in the fuel. A high ratio of light weight can only be used on VP30 24 volt specifications.
hydrocarbons can affect the characteristics of
combustion.
Group 3 (aviation kerosene fuels): Specification
Lubricity

This is the capability of the fuel to prevent pump

wear.
40
Maintenance Section
Fuel Specifications

These fuels need additives to achieve lubricity of Diesel fuels that meet the specifications in Table
650 micrometers wear scar and the reliability of 6 will help to provide maximum engine service
the fuel injection pump will be reduced. The fuel life and performance. In North America, diesel
injection pump is not covered by a warranty, even fuel that is identified as No. 2-D in “ASTM D975”
when the additives are included. generally meets the specifications. Table 6 is for
diesel fuels that are distilled from crude oil. Diesel
“JP5 MIL T5624 (Avcat FSII, NATO F44” fuels from other sources could exhibit detrimental
properties that are not defined or controlled by this
“JP8 T83133 (Avtur FSII, NATO F34” specification.

“Jet A” Table 6
Perkins Specifications for Distillate Diesel Fuel
“Jet A1, NATO F35, XF63”
Specifications Requirements ASTM Test
Low temperature fuels Aromatics 35% maximum “D1319”

Special fuels for use in cold weather may be Ash 0.02% maximum
“D482”
available for engine operation at temperatures (weight)
below 0 C (32 F). These fuels limit the formation Carbon Residue 0.35% maximum
of wax in the fuel oil at low temperatures. If wax “D524”
on 10% Bottoms (weight)
forms in the fuel oil, this could stop the flow of fuel
oil through the filter. Cetane Number 40 minimum (DI
engines) “D613”

Note: These fuels that lack lubricity may cause the Cloud Point The cloud
following problems: point must not
exceed the -
• Low engine power lowest expected
ambient
• Difficult starting in hot conditions or in cold temperature.
conditions Copper Strip No. 3 maximum
“D130”
Corrosion
• White smoke
Distillation 10% at 282 C
• Deterioration of emissions and misfire at certain (540 F)
operating conditions maximum
“D86”
90% at 360 C
Biofuel: Specification (680 F)
maximum
Biofuel: A 5% mix of RME to EN14214 in
Flash Point legal limit “D93”
conventional fuel is permitted.
API Gravity 30 minimum
“D287”
NOTICE 45 maximum
Water emulsion fuels: These fuels are not permitted
Pour Point 6 C (10 F)
minimum
“D97”
Refer to the following fuel specifications for below ambient
North America. temperature
Sulfur (1) 0.2% maximum “D3605”
The preferred fuels provide maximum engine or
service life and performance. The preferred fuels “D1552”
are distillate fuels. These fuels are commonly called
diesel fuel or gas oil. Kinematic 2.0 cSt minimum
Viscosity (2) and 4.5 cSt
“D445”
maximum at
The permissible fuels are crude oils or blended 40 C (104 F)
fuels. Use of these fuels can result in higher
maintenance costs and in reduced engine service Water and 0.1% maximum
“D1796”
life. Sediment
Water 0.1% maximum “D1744”
(continued)
 41
Maintenance Section
Fuel Specifications

(Table 6, contd) Table 7

Sediment 0.05% maximum Distillate Fuels (1)
“D473”
(weight)
Specification Grade
Gum and Resins 10 mg per 100
“D381” “MIL-T-5624R” JP-5
(3) mL maximum
Lubricity (4) 0.38 mm “ASTM D1655” Jet-A-1
(0.015 inch)
“D6079” “MIL-T-83133D” JP-8
maximum at
25 C (77 F) (1) The fuels that are listed in this Table may not meet the
requirements that are specified in the “Perkins Specifications
(1) Perkins fuel systems and engine components can operate on for Distillate Diesel Fuel” Table. Consult the supplier for the
high sulfur fuels. Fuel sulfur levels affect exhaust emissions. recommended additives in order to maintain the proper fuel
High sulfur fuels also increase the potential for corrosion of lubricity.
internal components. Fuel sulfur levels above 0.5 percent
may significantly shorten the oil change interval. For
additional information, see this publication, “Engine Oil” topic These fuels are lighter than the No. 2 grades of fuel.
(Maintenance Section). The cetane number of the fuels in Table 7 must be
(2) The values of the fuel viscosity are the values as the fuel at least 40. If the viscosity is below 1.4 cSt at 38 C
is delivered to the fuel injection pumps. If a fuel with a low (100 F), use the fuel only in temperatures below
viscosity is used, cooling of the fuel may be required to maintain
a 1.4 cSt viscosity at the fuel injection pump. Fuels with a high
0 C (32 F). Do not use any fuels with a viscosity
viscosity might require fuel heaters in order to bring down the of less than 1.2 cSt at 38 C (100 F). Fuel cooling
viscosity to a 20 cSt viscosity. may be required in order to maintain the minimum
(3) Follow the test conditions and procedures for gasoline (motor). viscosity of 1.4 cSt at the fuel injection pump.
(4) The lubricity of a fuel is a concern with low sulfur fuel. To
determine the lubricity of the fuel, use either the “ASTM D6078 There are many other diesel fuel specifications that
Scuffing Load Wear Test (SBOCLE)” or the “ASTM D6079 High
Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a are published by governments and by technological
fuel does not meet the minimum requirements, consult your societies. Usually, those specifications do not
fuel supplier. Do not treat the fuel without consulting the fuel review all the requirements that are addressed
supplier. Some additives are not compatible. These additives in this specification. To ensure optimum engine
can cause problems in the fuel system.
performance, a complete fuel analysis should be
obtained before engine operation. The fuel analysis
NOTICE should include all of the properties that are listed
Operating with fuels that do not meet the Perkins rec- in Table 6.
ommendations can cause the following effects: Start-
ing difficulty, poor combustion, deposits in the fuel in-
jectors, reduced service life of the fuel system, de-
posits in the combustion chamber, and reduced ser-
vice life of the engine.

NOTICE
Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel
must NOT be used in Perkins diesel engines. Severe
component wear and component failures will result if
HFO type fuels are used in engines that are configured
to use distillate fuel.

In extreme cold ambient conditions, you may

use the distillate fuels that are specified in Table
7. However, the fuel that is selected must meet
the requirements that are specified in Table 6.
These fuels are intended to be used in operating
temperatures that are down to −54 C (−65 F).
42
Maintenance Section
Cooling System Specifications

Cooling System Water

Specifications Water is used in the cooling system in order to
transfer heat.

i01908149 Distilled water or deionized water is

recommended for use in engine cooling systems.
General Coolant Information
DO NOT use the following types of water in cooling
systems: Hard water, softened water that has been
conditioned with salt, and sea water.
NOTICE
Never add coolant to an overheated engine. Engine If distilled water or deionized water is not available,
damage could result. Allow the engine to cool first. use water with the properties that are listed in Table
8.

NOTICE Table 8
If the engine is to be stored in, or shipped to an area Perkins Minimum Acceptable Water Requirements
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temper- Property Maximum Limit
ature or drained completely to prevent damage. Chloride (Cl) 40 mg/L
Sulfate (SO4) 100 mg/L
NOTICE
Frequently check the specific gravity of the coolant for Total Hardness 170 mg/L
proper freeze protection or for anti-boil protection. Total Solids 340 mg/L
Acidity pH of 5.5 to 9.0
Clean the cooling system for the following reasons:
For a water analysis, consult one of the following
• Contamination of the cooling system sources:
• Overheating of the engine • Local water utility company
• Foaming of the coolant • Agricultural agent
NOTICE • Independent laboratory
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
Additives
proper operating temperature. Cooling system prob-
Additives help to protect the metal surfaces of
lems can develop without water temperature regula-
the cooling system. A lack of coolant additives
tors.
or insufficient amounts of additives enable the
following conditions to occur:
Many engine failures are related to the cooling
system. The following problems are related to • Corrosion
cooling system failures: Overheating, leakage of
the water pump, and plugged radiators or heat • Formation of mineral deposits
exchangers.
• Rust
These failures can be avoided with proper cooling
system maintenance. Cooling system maintenance • Scale
is as important as maintenance of the fuel system
and the lubrication system. Quality of the coolant • Foaming of the coolant
is as important as the quality of the fuel and the
lubricating oil. Many additives are depleted during engine
operation. These additives must be replaced
Coolant is normally composed of three elements: periodically. .
Water, additives, and glycol.
 43
Maintenance Section
Cooling System Specifications

Additives must be added at the proper Table 10

concentration. Overconcentration of additives can Propylene Glycol
cause the inhibitors to drop out-of-solution. The
deposits can enable the following problems to Concentration
Freeze Anti-Boil
occur: Protection Protection
50 Percent −29 C (−20 F) 106 C (223 F)
• Formation of gel compounds
• Reduction of heat transfer To check the concentration of glycol in the coolant,
measure the specific gravity of the coolant.
• Leakage of the water pump seal
i01908218
• Plugging of radiators, coolers, and small
passages Coolant Recommendations
Glycol
Glycol in the coolant helps to provide protection The antifreeze that is used must meet the standard
against the following conditions: of corrosion protection that is specified in one of the
following specifications:
• Boiling
“BS 6580 - 1992”
• Freezing
“ASTM D3306”
• Cavitation of the water pump
These specifications define the requirements for
For optimum performance, Perkins recommends a commercial antifreeze. It is also acceptable to use
1:1 mixture of a water/glycol solution. an antifreeze that has been designed for use in a
heavy-duty application.
Note: Use a mixture that will provide protection
against the lowest ambient temperature. The manufacturers recommendations for the
maintenance of the coolant and the replacement of
Note: 100 percent pure glycol will freeze at a the coolant must be followed at all times.
temperature of −23 C (−9 F).
Failure to follow these requirements may invalidate
Most conventional coolant/antifreezes use ethylene any warranty claim.
glycol. Propylene glycol may also be used. In a 1:1
mixture with water, ethylene and propylene glycol
provide similar protection against freezing and
boiling. See Tables 9 and 10.
Table 9
Ethylene Glycol
Freeze Boil
Concentration
Protection Protection
50 Percent −36 C (−33 F) 106 C (223 F)
60 Percent −51 C (−60 F) 111 C (232 F)

NOTICE
Do not use propylene glycol in concentrations that ex-
ceed 50 percent glycol because of propylene glycol’s
reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
boiling or freezing.
44
Maintenance Section
Refill Capacities

Refill Capacities 1104 Engine

Table 13
i01929409 1104 Naturally Aspirated Engine
Refill Capacities Compartment or System Liters Quarts
Engine Only 10.4 11
External cooling system capacity
(OEM recommendation) (1)
Lubrication System
Total Cooling System (2)
The refill capacities for the engine crankcase (1) The external cooling system includes a radiator or an
reflect the approximate capacity of the crankcase expansion tank with the following components: heat exchanger,
or sump plus standard oil filters. Auxiliary oil filter aftercooler, and piping. Refer to the OEM specifications. Enter
systems will require additional oil. Refer to the the value for the external system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine
OEM specifications for the capacity of the auxiliary
cooling system plus the capacity for the external cooling
oil filter. Refer to the Operation and Maintenance system. Enter the total in this row.
Manual, “Maintenance Section” for more information
on Lubricant Specifications. Table 14
1104 Turbocharged Engine
1104 Engine
Compartment or System Liters Quarts
Table 11
Engine Only 11.4 12
1104 Engine
External cooling System capacity
Compartment or System Liters Quarts (OEM recommendation) (1)
Standard Oil Sump for the Engine Total Cooling System (2)
7.3 8
Crankcase (1) (1) The external cooling system includes a radiator or an
(1) These values are the approximate capacities for the crankcase expansion tank with the following components: heat exchanger,
oil sump which include the standard factory installed oil filters. aftercooler, and piping. Refer to the OEM specifications. Enter
Engines with auxiliary oil filters will require additional oil. Refer the value for the external cooling system capacity in this row.
to the OEM specifications for the capacity of the auxiliary oil (2) The Total Cooling System includes the capacity for the engine
filter. cooling system plus the capacity for the external cooling
system. Enter the total in this row.

1103 Engine
Table 12
1103 Engine
Compartment or System Liters Quarts
Standard Oil Sump for the Engine
7.4 8
Crankcase (1)
(1) These values are the approximate capacities for the crankcase
oil sump which include the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.

Cooling System
To maintain the cooling system, the Total Cooling
System capacity must be known. The approximate
capacity for the engine cooling system is listed
below. External System capacities will vary among
applications. Refer to the OEM specifications for the
External System capacity. This capacity information
will be needed in order to determine the amount
of coolant/antifreeze that is required for the Total
Cooling System.
 45
Maintenance Section
Refill Capacities

1103 Engine
Table 15
1103 Naturally Aspirated Engine without an oil cooler
Compartment or System Liters Quarts
Engine Only 4.21 4
External cooling system capacity
(OEM recommendation) (1)
Total Cooling System (2)
(1) The external cooling system includes a radiator or an
expansion tank with the following components: heat exchanger,
aftercooler, and piping. Refer to the OEM specifications. Enter
the value for the external system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine
cooling system plus the capacity for the external cooling
system. Enter the total in this row.

Table 16
1103 Naturally Aspirated Engines and Turbocharged
Engines with an oil cooler
Compartment or System Liters Quarts
Engine Only 4.43 4.02
External cooling system capacity
(OEM recommendation) (1)
Total Cooling System (2)
(1) The external cooling system includes a radiator or an
expansion tank with the following components: heat exchanger,
aftercooler, and piping. Refer to the OEM specifications. Enter
the value for the external system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine
cooling system plus the capacity for the external cooling
system. Enter the total in this row.
46
Maintenance Section
Maintenance Interval Schedule

i01928701 Every 1000 Service Hours

Maintenance Interval Schedule Engine Valve Lash - Inspect/Adjust ...................... 60

Every 2000 Service Hours

Ensure that the Safety Information, Warnings, Aftercooler Core - Inspect ..................................... 47
and Instructions are read and understood Alternator - Inspect ............................................... 48
before operation or maintenance procedures are Engine Mounts - Inspect ....................................... 56
performed. Starting Motor - Inspect ........................................ 67
Turbocharger - Inspect .......................................... 67
Before each consecutive interval is performed, all Water Pump - Inspect ........................................... 68
of the maintenance requirements from the previous
interval must also be performed. Every 2 Years

Note: For engine cooling systems that contain Cooling System Coolant - Change ....................... 50
Perkins antifreeze, replace the coolant in the engine
cooling system at 2 yearly intervals. For engine Every 4000 Service Hours
cooling systems that contain an inhibitor, replace Aftercooler Core - Clean/Test ............................... 47
the coolant in the engine cooling system at 6
monthly intervals.

When Required
Battery - Replace .................................................. 49
Battery or Battery Cable - Disconnect .................. 50
Engine - Clean ...................................................... 52
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 53
Engine Air Cleaner Element (Single Element) -
Replace ............................................................... 55
Engine Oil Sample - Obtain .................................. 57
Fuel Injector - Test/Change ................................... 60
Fuel System - Prime ............................................. 61
Severe Service Application - Check ...................... 66

Daily
Alternator and Fan Belts - Inspect/Adjust/
Replace ............................................................... 48
Cooling System Coolant Level - Check ................ 51
Driven Equipment - Check .................................... 52
Engine Air Cleaner Service Indicator - Inspect ..... 55
Engine Oil Level - Check ...................................... 56
Fuel System Primary Filter/Water Separator -
Drain ................................................................... 62
Walk-Around Inspection ........................................ 68

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 49
Cooling System Coolant - Test/Add ...................... 51
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 53
Engine Ground - Inspect/Clean ............................ 56
Engine Oil and Filter - Change ............................. 57
Fuel System Primary Filter/Water Separator Element
- Replace ............................................................. 62
Fuel System Secondary Filter - Replace .............. 63
Hoses and Clamps - Inspect/Replace .................. 64
Radiator - Clean .................................................... 65
 47
Maintenance Section
Aftercooler Core - Clean/Test

i01853891 Inspect the aftercooler for these items: damaged

fins, corrosion, dirt, grease, insects, leaves, oil, and
Aftercooler Core - Clean/Test other debris. Clean the aftercooler, if necessary.

For air-to-air aftercoolers, use the same methods

that are used for cleaning radiators.
1. Remove the core. Refer to the OEM information
for the correct procedure.

2. Turn the aftercooler core upside-down in order

to remove debris. Personal injury can result from air pressure.

NOTICE Personal injury can result without following prop-

Do not use a high concentration of caustic cleaner to er procedure. When using pressure air, wear a pro-
clean the core. A high concentration of caustic cleaner tective face shield and protective clothing.
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of Maximum air pressure at the nozzle must be less
cleaner. than 205 kPa (30 psi) for cleaning purposes.

3. Back flush the core with a suitable cleaner. Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
4. Steam clean the core in order to remove any of the fan’s air flow. Hold the nozzle approximately
residue. Flush the fins of the aftercooler core. 6 mm (.25 inch) away from the fins. Slowly move
Remove any other trapped debris. the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the
5. Wash the core with hot, soapy water. Rinse the tubes.
core thoroughly with clean water.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
Personal injury can result from air pressure. both sides.

Personal injury can result without following prop- Use a degreaser and steam for removal of oil and
er procedure. When using pressure air, wear a pro- grease. Clean both sides of the core. Wash the core
tective face shield and protective clothing. with detergent and hot water. Thoroughly rinse the
core with clean water.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
6. Dry the core with compressed air. Direct the air of debris and drying of the core. Stop the engine.
in the reverse direction of the normal flow. Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
7. Inspect the core in order to ensure cleanliness. necessary.
Pressure test the core. If necessary, repair the
core. Inspect the fins for damage. Bent fins may be
opened with a “comb”.
8. Install the core. Refer to the OEM information for
the correct procedure. Note: If parts of the aftercooler system are repaired
or replaced, a leak test is highly recommended.

i01841503 Inspect these items for good condition: Welds,

mounting brackets, air lines, connections, clamps,
Aftercooler Core - Inspect and seals. Make repairs, if necessary.

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.
48
Maintenance Section
Alternator - Inspect

i01908658

Alternator - Inspect

Perkins recommends a scheduled inspection of

the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect
the ammeter (if equipped) during engine operation
in order to ensure proper battery performance
and/or proper performance of the electrical system.
Make repairs, as required.

Check the alternator and the battery charger for

g01003936
proper operation. If the batteries are properly Illustration 18
charged, the ammeter reading should be very near Typical example
zero. All batteries should be kept charged. The (1) Burroughs Gauge
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold, Fit the gauge (1) at the center of the longest free
the battery will not crank the engine. When the length and check the tension. The correct tension
engine is not run for long periods of time or if the is 535 N (120 lb). If the tension of the belt is below
engine is run for short periods, the batteries may 250 N (56 lb) adjust the belt to 535 N (120 lb).
not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge. If twin belts are installed, check and adjust the
tension on both belts.
i01929797

Alternator and Fan Belts - Adjustment

Inspect/Adjust/Replace

Inspection
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that
are worn or damaged.

For applications that require multiple drive belts,

replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to
carry more load because the older belt is stretched. Illustration 19
g01003939
The additional load on the new belt could cause the
new belt to break. 1. Loosen The alternator pivot bolt (2) and the bolt
(3).
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose 2. Move the alternator in order to increase or
belts may slip enough to cause overheating. decrease the belt tension. Tighten the alternator
pivot bolt and the link bolt to 22 N·m (16 lb ft).(1).
To accurately check the belt tension, a suitable
gauge should be used.
Replacement
Refer to the Disassembly and Assembly Manual
for the installation procedure and the removal
procedure for the belt.
 49
Maintenance Section
Battery - Replace

i01915808 i01908638

Battery - Replace Battery Electrolyte Level -

Check

When the engine is not run for long periods of

Batteries give off combustible gases which can time or when the engine is run for short periods,
explode. A spark can cause the combustible gas- the batteries may not fully recharge. Ensure a full
es to ignite. This can result in severe personal in- charge in order to help prevent the battery from
jury or death. freezing. If batteries are properly charged, ammeter
reading should be very near zero.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced. All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.

The battery cables or the batteries should not be 1. Remove the filler caps. Maintain the electrolyte
removed with the battery cover in place. The bat- level to the “FULL” mark on the battery.
tery cover should be removed before any servic-
ing is attempted. If the addition of water is necessary, use distilled
water. If distilled water is not available use
Removing the battery cables or the batteries with clean water that is low in minerals. Do not use
the cover in place may cause a battery explosion artificially softened water.
resulting in personal injury.
2. Check the condition of the electrolyte with a
1. Turn the key start switch to the OFF position. suitable battery tester.
Remove the key and all electrical loads.
3. Keep the batteries clean.
2. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the ground plane. Clean the battery case with one of the following
Disconnect the cable from the NEGATIVE “-” cleaning solutions:
battery terminal.
• A mixture of 0.1 kg (0.2 lb) of baking soda and
3. The POSITIVE “+” cable connects the POSITIVE 1 L (1 qt) of clean water
“+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+” • A mixture of 0.1 L (0.11 qt) of ammonia and
battery terminal. 1 L (1 qt) of clean water

Note: Always recycle a battery. Never discard a Thoroughly rinse the battery case with clean
battery. Return used batteries to an appropriate water.
recycling facility.
Use a fine grade of sandpaper to clean the
4. Remove the used battery. terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
5. Install the new battery. remove material excessively. Excessive removal
of material can cause the clamps to not fit
Note: Before the cables are connected, ensure that properly. Coat the clamps and the terminals with
the key start switch is OFF. a suitable silicone lubricant or petroleum jelly.

6. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.

7. Connect the cable from the ground plane to the

NEGATIVE “-” battery terminal.
50
Maintenance Section
Battery or Battery Cable - Disconnect

i01492654
NOTICE
Battery or Battery Cable - Do not drain the coolant while the engine is still hot and
Disconnect the system is under pressure because dangerous hot
coolant can be discharged.

Note: The radiator may not have been provided by

Perkins. The following is a general procedure for
changing the coolant. Refer to the OEM information
The battery cables or the batteries should not be for the correct procedure.
removed with the battery cover in place. The bat-
tery cover should be removed before any servic- 1. Ensure that the vehicle is on level ground.
ing is attempted.
2. Remove the filler cap of the cooling system.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion 3. Remove the drain plug (1) from the side of the
resulting in personal injury. cylinder block in order to drain the engine.
Ensure that the drain hole is not restricted.
1. Turn the start switch to the OFF position. Turn the
4. Open the radiator drain tap or remove the drain
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads. plug at the bottom of the radiator in order to
drain the radiator. If the radiator does not have a
radiator drain tap or a drain plug, disconnect the
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that hose at the bottom of the radiator.
the cable cannot contact the terminal. When four
5. Flush the coolant system with clean water.
12 volt batteries are involved, the negative side
of two batteries must be disconnected.
6. Install the drain plugs and close the radiator
drain tap. Install the radiator hose if the radiator
3. Tape the leads in order to help prevent accidental
starting. hose was previously removed.

7. Fill the system with an approved antifreeze

4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables. mixture. The maximum flow rate is 1 L
(0.2200 Imp gal) per minute in order to fill the
system. Install the filler cap.
i01929799
8. Run the engine and check for coolant leaks.
Cooling System Coolant -
Change

g01003928
Illustration 20
Drain plug
 51
Maintenance Section
Cooling System Coolant - Test/Add

i01914623

Cooling System Coolant -

Pressurized System: Hot coolant can cause seri-
Test/Add 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 pres-
Check the specific gravity of the sure.
coolant
5. Remove the filler cap of the cooling system.

6. Drain some of the coolant from the cooling

system into a suitable container.

7. Use a special hydrometer that will check

the temperature and the specific gravity of
the coolant, and follow the manufacturer’s
instructions.

Note: If a special thermo-hydrometer for coolant is

not available, put an hydrometer and a separate
thermometer into the antifreeze mixture and check
the readings on both instruments. Compare the
readings with the data in illustration 21.

Note: If necessary, fill the system or replenish the

coolant in the system with premixed coolant of the
correct strength. Perkins POWERPART antifreeze
with a concentration of 50% will give protection
against frost to a temperature of −35 C (−31 F).
Illustration 21 g00997964 The solution will also protect against corrosion. This
is especially important when there are aluminum
The chart for the Specific gravity
components in the cooling circuit.
A = Percentage of antifreeze by volume
B = The temperature of the mixture in F 8. Adjust the strength of the mixture if it is
C = Specific gravity necessary.
E = The temperature of the solution in C
i01920057
The following procedure must be used to measure
coolant that contains antifreeze: Cooling System Coolant Level
1. Ensure that the engine is on level ground. - Check
2. Operate the engine until the coolant temperature
opens the thermostat. Continue to run the engine
until the coolant has circulated around the Note: The cooling system may not have been
cooling system. provided by Perkins. The procedure that follows
is for a typical cooling system. Refer to the OEM
3. Stop the engine. information for the correct procedures.

4. Allow the engine to cool until the temperature is Check the coolant level when the engine is stopped
below 60 C (140 F). and cool.
52
Maintenance Section
Driven Equipment - Check

i00174798

Driven Equipment - Check

Refer to the OEM specifications for more information

on the following maintenance recommendations for
the driven equipment:

• Inspection
• Adjustment

g00285520
• Lubrication
Illustration 22
Cooling system filler cap • Other maintenance recommendations
Perform any maintenance for the driven equipment
which is recommended by the OEM.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, i01930350
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Engine - Clean
pressure cap slowly in order to relieve the pres-
sure.

1. Remove the cooling system filler cap slowly in

order to relieve pressure.
Personal injury or death can result from high volt-
age.
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
Moisture can create paths of electrical conductiv-
equipped with a sight glass, maintain the coolant
ity.
level to the proper level in the sight glass.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “DO
NOT OPERATE”.

NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.

NOTICE
Failure to protect some engine components from
g00103639
washing may make your engine warranty invalid.
Illustration 23 Allow the engine to cool for one hour before washing
Typical filler cap gaskets the engine.

3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the Periodic cleaning of the engine is recommended.
cooling system filler cap if the filler cap gaskets Steam cleaning the engine will remove accumulated
are damaged. Reinstall the cooling system filler oil and grease. A clean engine provides the
cap. following benefits:

4. Inspect the cooling system for leaks. • Easy detection of fluid leaks
• Maximum heat transfer characteristics
 53
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

• Ease of maintenance Replace the dirty air cleaner elements with clean air
cleaner elements. Before installation, the air cleaner
Note: Caution must be used in order to prevent elements should be thoroughly checked for tears
electrical components from being damaged by and/or holes in the filter material. Inspect the gasket
excessive water when the engine is cleaned. or the seal of the air cleaner element for damage.
Pressure washers and steam cleaners should not Maintain a supply of suitable air cleaner elements
be directed at any electrical connectors or the for replacement purposes.
junction of cables into the rear of the connectors.
Avoid electrical components such as the alternator Dual Element Air Cleaners
and the starter. Protect the fuel injection pump from
fluids in order to wash the engine. The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner
i01915869
element. The primary air cleaner element can be
used up to six times if the element is properly
Engine Air Cleaner Element cleaned and properly inspected. The primary
air cleaner element should be replaced at least
(Dual Element) - Clean/Replace one time per year. This replacement should be
performed regardless of the number of cleanings.

The secondary air cleaner element is not serviceable

NOTICE or washable. Refer to the OEM information for
Never run the engine without an air cleaner element instructions in order to replace the secondary air
installed. Never run the engine with a damaged air cleaner element. When the engine is operating in
cleaner element. Do not use air cleaner elements with environments that are dusty or dirty, air cleaner
damaged pleats, gaskets or seals. Dirt entering the elements may require more frequent replacement.
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.

NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

Note: The air filter system may not have been
provided by Perkins. The procedure that follows
is for a typical air filter system. Refer to the OEM
g00736431
information for the correct procedure. Illustration 24
(1) Cover
If the air cleaner element becomes plugged, the (2) Primary air cleaner element
air can split the material of the air cleaner element. (3) Secondary air cleaner element
Unfiltered air will drastically accelerate internal (4) Air inlet
engine wear. Refer to the OEM information for the
correct air cleaner elements for your application. 1. Remove the cover. Remove the primary air
cleaner element.
• Check the precleaner (if equipped) and the dust 2. The secondary air cleaner element should be
bowl daily for accumulation of dirt and debris.
Remove any dirt and debris, as needed. removed and discarded for every three cleanings
of the primary air cleaner element.
• Operating conditions (dust, dirt and debris) may Note: Refer to “Cleaning the Primary Air Cleaner
require more frequent service of the air cleaner
element. Elements”.

3. Cover the air inlet with tape in order to keep dirt

• The air cleaner element should be replaced out.
at least one time per year. This replacement
should be performed regardless of the number
of cleanings. 4. Clean the inside of the air cleaner cover and
body with a clean, dry cloth.
54
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

5. Remove the tape for the air inlet. Install the Pressurized Air
secondary air cleaner element. Install a primary
air cleaner element that is new or cleaned. Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
6. Install the air cleaner cover. than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with
7. Reset the air cleaner service indicator. a maximum pressure of 207 kPa (30 psi).

Cleaning the Primary Air Cleaner

Elements
NOTICE
Observe the following guidelines if you attempt to
clean the filter element:

Do not tap or strike the filter element in order to remove

dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove g00281692

the dust from the filter element. Air pressure must not Illustration 25
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter Note: When the primary air cleaner elements are
element. Take extreme care in order to avoid damage cleaned, always begin with the clean side (inside)
to the pleats. in order to force dirt particles toward the dirty side
(outside).
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to Aim the hose so that the air flows inside the element
engine components. along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
Refer to the OEM information in order to determine could be forced further into the pleats.
the number of times that the primary filter element
can be cleaned. When the primary air cleaner Note: Refer to “Inspecting the Primary Air Cleaner
element is cleaned, check for rips or tears in the Elements”.
filter material. The primary air cleaner element
should be replaced at least one time per year. This Vacuum Cleaning
replacement should be performed regardless of the
number of cleanings. Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
NOTICE cleaning because of a dry, dusty environment.
Do not clean the air cleaner elements by bumping or Cleaning with pressurized air is recommended
tapping. This could damage the seals. Do not use el- prior to vacuum cleaning. Vacuum cleaning will not
ements with damaged pleats, gaskets or seals. Dam- remove deposits of carbon and oil.
aged elements will allow dirt to pass through. Engine
damage could result. Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
Visually inspect the primary air cleaner elements
before cleaning. Inspect the air cleaner elements
for damage to the seal, the gaskets, and the outer
cover. Discard any damaged air cleaner elements.

There are two common methods that are used to

clean primary air cleaner elements:

• Pressurized air
• Vacuum cleaning
 55
Maintenance Section
Engine Air Cleaner Element (Single Element) - Replace

Inspecting the Primary Air Cleaner

Elements

g00109823
Illustration 27
(1) Air cleaner element. (2) Clamp.
g00281693
Illustration 26
1. Loosen clamp (2) which fastens air cleaner
Inspect the clean, dry primary air cleaner element. element (1) to the air inlet. Remove the dirty air
Use a 60 watt blue light in a dark room or in a cleaner element and clamp.
similar facility. Place the blue light in the primary
air cleaner element. Rotate the primary air cleaner 2. Install clamp (2) on new air cleaner element (1).
element. Inspect the primary air cleaner element for
tears and/or holes. Inspect the primary air cleaner 3. Install new air cleaner element (1) to the air inlet
element for light that may show through the filter and tighten clamp (2). Refer to the OEM Manual
material. If it is necessary in order to confirm the for more information on torque specifications.
result, compare the primary air cleaner element
to a new primary air cleaner element that has the
i01909507
same part number.
Engine Air Cleaner Service
Do not use a primary air cleaner element that has
any tears and/or holes in the filter material. Do not Indicator - Inspect
use a primary air cleaner element with damaged
pleats, gaskets or seals. Discard damaged primary
air cleaner elements.
Some engines may be equipped with a different
service indicator.
i01929798
Some engines are equipped with a differential
Engine Air Cleaner Element gauge for inlet air pressure. The differential gauge
(Single Element) - Replace for inlet air pressure displays the difference in the
pressure that is measured before the air cleaner
element and the pressure that is measured after
the air cleaner element. As the air cleaner element
becomes dirty, the pressure differential rises. If your
NOTICE
engine is equipped with a different type of service
Never service the air cleaner element with the engine
indicator, follow the OEM recommendations in order
running since this will allow dirt to enter the engine.
to service the air cleaner service indicator.

Note: This air cleaner is not provided by Perkins. The service indicator may be mounted on the air
cleaner element or in a remote location.
56
Maintenance Section
Engine Ground - Inspect/Clean

• Clean the grounding stud on the starter motor

and the terminals with a clean cloth.

• If the connections are corroded, clean the

connections with a solution of baking soda and
water.

• Keep the grounding stud and the strap clean and

coated with suitable grease or petroleum jelly.

i01908586

Engine Mounts - Inspect

g00103777
Illustration 28
Typical service indicator
Note: The engine mounts may not have been
supplied for this installation by Perkins. Refer to
Observe the service indicator. The air cleaner
the OEM information for further information on the
element should be cleaned or the air cleaner
engine mounts and the correct bolt torque.
element should be replaced when one of the
following conditions occur:
Inspect the engine mounts for deterioration and for
correct bolt torque. Engine vibration can be caused
• The yellow diaphragm enters the red zone. by the following conditions:
• The red piston locks in the visible position. • Improper mounting of the engine
Test the Service Indicator • Deterioration of the engine mounts
Service indicators are important instruments. Any engine mount that shows deterioration should
be replaced. Refer to the OEM information for the
• Check for ease of resetting. The service indicator recommended torques.
should reset in less than three pushes.
i01907673
• Check the movement of the yellow core when the
engine is accelerated to the engine rated speed. Engine Oil Level - Check
The yellow core should latch approximately at the
greatest vacuum that is attained.

If the service indicator does not reset easily, or if the

yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the
new service indicator will not reset, the hole for the Hot oil and hot components can cause personal
service indicator may be restricted. injury. Do not allow hot oil or hot components to
contact the skin.
The service indicator may need to be replaced
frequently in environments that are severely dusty.

i01941505

Engine Ground - Inspect/Clean

g00998024
Illustration 29
Inspect the wiring harness for good connections. (Y) “ADD” mark. (X) “FULL” mark.

Perkins use the starter motor in order to ground

the engine. Check the connection on the starter NOTICE
motor at every oil change. Ground wires and straps Perform this maintenance with the engine stopped.
should be combined at engine grounds. All grounds
should be tight and free of corrosion.
 57
Maintenance Section
Engine Oil Sample - Obtain

Note: Ensure that the engine is either level or that • The date of the sample
the engine is in the normal operating position in
order to obtain a true level indication. • Engine model
Note: After the engine has been switched OFF, • Engine number
allow the engine oil to drain to the oil pan before
checking the oil level. • Service hours on the engine
1. Maintain the oil level between the “ADD” mark • The number of hours that have accumulated
(Y) and the “FULL” mark (X) on the engine oil since the last oil change
dipstick. Do not fill the crankcase above the
“FULL” mark (X). • The amount of oil that has been added since the
last oil change
NOTICE
Operating your engine when the oil level is above the Ensure that the container for the sample is clean
“FULL” mark could cause your crankshaft to dip into and dry. Also ensure that the container for the
the oil. The air bubbles created from the crankshaft sample is clearly labelled.
dipping into the oil reduces the oil’s lubricating char-
acteristics and could result in the loss of power. To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap. To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
i01942173

Engine Oil Sample - Obtain The sample can be checked for the following: the
quality of the oil, the existence of any coolant in the
oil, the existence of any ferrous metal particles in
the oil, and the existence of any nonferrous metal
particles in the oil.
The condition of the engine lubricating oil may be
checked at regular intervals as part of a preventive i01929323
maintenance program. Perkins include an oil
sampling valve as an option only on the 1104 Engine Oil and Filter - Change
engine. The oil sampling valve (if equipped) is
included in order to regularly sample the engine
lubricating oil. The oil sampling valve is positioned
on the oil filter head or the oil sampling valve is
positioned on the cylinder block.
Hot oil and hot components can cause personal
Perkins recommends using a sampling valve in
injury. Do not allow hot oil or hot components to
order to obtain oil samples. The quality and the
contact the skin.
consistency of the samples are better when a
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be Do not drain the oil when the engine is cold. As
obtained during normal engine operation. the oil cools, suspended waste particles settle
on the bottom of the oil pan. The waste particles
Obtain the Sample and the Analysis are not removed with the draining cold oil. Drain
the crankcase with the engine stopped. Drain the
crankcase with the oil warm. This draining method
allows the waste particles that are suspended in the
oil to be drained properly.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to Failure to follow this recommended procedure will
contact the skin. cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
In order to help obtain the most accurate analysis,
record the following information before an oil sample
is taken:
58
Maintenance Section
Engine Oil and Filter - Change

Drain the Engine Oil 2. Cut the oil filter open with a suitable tool. Break
apart the pleats and inspect the oil filter for metal
debris. An excessive amount of metal debris in
the oil filter may indicate early wear or a pending
failure.

Use a magnet to differentiate between the

ferrous metals and the nonferrous metals that
are found in the oil filter element. Ferrous metals
may indicate wear on the steel and cast iron
parts of the engine.

Nonferrous metals may indicate wear on the

aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
g01003623 turbocharger bearings, and cylinder heads.
Illustration 30
Oil drain plug
Due to normal wear and friction, it is not
After the engine has been run at the normal uncommon to find small amounts of debris in
operating temperature, stop the engine. Use one of the oil filter.
the following methods to drain the engine crankcase
oil:

• If the engine is equipped with a drain valve, turn

the drain valve knob counterclockwise in order to
drain the oil. After the oil has drained, turn the
drain valve knob clockwise in order to close the
drain valve.

• If the engine is not equipped with a drain valve,

remove the oil drain plug (1) in order to allow
the oil to drain. If the engine is equipped with a
shallow sump, remove the bottom oil drain plugs
from both ends of the oil pan.
g01003628
Illustration 31
After the oil has drained, the oil drain plugs should
be cleaned and installed. If necessary, renew the O (2) Filter head
(3) O ring seal
ring seal on the drain plug.
3. Clean the sealing surface of the oil filter head
Some types of oil pans have oil drain plugs that are
(2). Ensure that the union (not shown) in the oil
on both sides of the oil pan, because of the shape
filter head is secure.
of the pan. This type of oil pan requires the engine
oil to be drained from both plugs.
4. Apply clean engine oil to the O ring seal (3) on
the oil filter.
Replace the Spin-on Oil Filter
NOTICE
NOTICE Do not fill the oil filters with oil before installing them.
Perkins oil filters are manufactured to Perkins speci- This oil would not be filtered and could be contaminat-
fications. Use of an oil filter that is not recommended ed. Contaminated oil can cause accelerated wear to
by Perkins could result in severe damage to the en- engine components.
gine bearings, crankshaft, etc., as a result of the larger
waste particles from unfiltered oil entering the engine 5. Install the oil filter. Tighten the oil filter by hand
lubricating system. Only use oil filters recommended according to the instructions that are shown on
by Perkins. the oil filter. Do not overtighten the oil filter.

1. Remove the oil filter with a suitable tool.

Note: The following actions can be carried out as

part of the preventive maintenance program.
 59
Maintenance Section
Engine Oil and Filter - Change

Replace the Element for the Oil Note: Some engines may have a horizontally
mounted oil filter. This oil filter has a drain plug that
Filter is located in the oil filter head.

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual for more information on
lubricant specifications. Fill the crankcase with
the proper amount of oil. Refer to the Operation
and Maintenance Manual for more information
on refill capacities.

NOTICE
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
Illustration 32 g01003662 facturer’s recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
(1) Drain plug
(2) Square hole
(3) Filter bowl
NOTICE
1. Place a suitable container under the oil filter. To prevent crankshaft bearing damage, crank the en-
Remove the drain plug (1) and the seal, from gine with the fuel OFF. This will fill the oil filters before
the oil filter. starting the engine. Do not crank the engine for more
than 30 seconds.
2. Locate a suitable wrench into the square hole (2)
in order to remove the filter bowl (3). 2. Start the engine and run the engine at “LOW
IDLE” for two minutes. Perform this procedure in
3. Remove the filter bowl (3) and remove the order to ensure that the lubrication system has
element from the filter bowl. Clean the filter bowl. oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.

3. Stop the engine and allow the oil to drain back

to the sump for a minimum of ten minutes.

g00998024
Illustration 34
(Y) “ADD” mark. (X) “FULL” mark.
g01003675
Illustration 33
(4) O ring seal 4. Remove the oil level gauge in order to check the
(5) Element oil level. Maintain the oil level between the “ADD”
(6) Filter head and “FULL” marks on the engine oil dipstick.

4. Install a new O ring (4) onto the filter bowl and

lubricate the O ring with clean engine oil. Install
the filter element (5) into the filter bowl.

5. Install the filter bowl into the oil filter head (6).
Tighten the filter bowl to the following torque
25 N·m (18 lb ft).

6. Install a new seal onto the drain plug (1) and

install the drain plug into the oil filter. Tighten the
drain plug to the following torque 12 N·m (8 lb ft).
60
Maintenance Section
Engine Valve Lash - Inspect/Adjust

i01933316
NOTICE
Engine Valve Lash - Do not allow dirt to enter the fuel system. Thoroughly
Inspect/Adjust clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

This maintenance is recommended by Perkins as

part of a lubrication and preventive maintenance NOTICE
schedule in order to help provide maximum engine If a fuel injector is suspected of operating outside of
life. normal parameters it should be removed by a qualified
technician. The suspect fuel injector should be taken
to an authorised agent for inspection.
NOTICE
Only qualified service personel should perform this
maintenance. Refer to the Service Manual or your au- Regular maintenance of the fuel injectors is not
thorized Perkins dealer or your Perkins distruibutor for necessary. The fuel injectors should not be cleaned
the complete valve lash adjustment procedure. as cleaning with incorrect tools can damage the
nozzle. The fuel injectors should be renewed only
Operation of Perkins engines with incorrect valve lash if a fault with the fuel injectors occurs. Some of the
can reduce engine efficiency, and also reduce engine problems that may indicate that new fuel injectors
component life. are needed are listed below:

• The engine will not start or the engine is difficult

to start.

Ensure that the engine can not be started while • Not enough power
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor • The engine misfires or the engine runs erratically.
to turn the flywheel.
• High fuel consumption
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea- • Black exhaust smoke
suring/adjusting valve lash clearance.
• The engine knocks or there is vibration in the
Ensure that the engine is stopped before measuring engine.
the valve lash. The engine valve lash can be
inspected and adjusted when the temperature of • Excessive engine temperature
the engine is hot or cold.
Removal and Installation of the
Refer to Systems Operation/Testing and Adjusting,
“Engine Valve Lash - Inspect/Adjust” for more
Fuel Injectors
information.

i01946008
Work carefully around an engine that is running.
Fuel Injector - Test/Change Engine parts that are hot, or parts that are moving,
can cause personal injury.

Make sure that you wear eye protection at all

Fuel leaked or spilled onto hot surfaces or electri- times during testing. When fuel injection nozzles
cal components can cause a fire. are tested, test fluids travel through the orifices
of the nozzle tip with high pressure. Under this
amount of pressure, the test fluid can pierce the
skin and cause serious injury to the operator.
Always keep the tip of the fuel injection nozzle
pointed away from the operator and into the fuel
collector and extension.
 61
Maintenance Section
Fuel System - Prime

NOTICE
If your skin comes into contact with high pressure fuel,
obtain medical assistence immediately.

Operate the engine at a fast idle speed in order to

identify the faulty fuel injector. Individually loosen
and tighten the union nut for the high pressure
pipe to each fuel injector. Do not loosen the union
nut more than half a turn. There will be little effect
on the engine speed when the union nut to the
faulty fuel injection nozzle is loosened. Refer to
the Disassembly and Assembly Manual for more
information. Consult your authorized Perkins dealer
g01003929
or your Perkins distributor for assistance. Illustration 35
Injector nuts

i01929324
Note: Damage to the fuel injection pump, to the
Fuel System - Prime battery, and to the starter motor can occur if the
starter motor is used excessively to purge the air
from the fuel system.

If air enters the fuel system, the air must be purged 4. Loosen the flare nuts (1) for the high pressure
from the fuel system before the engine can be fuel lines on all of the fuel injectors.
started. Air can enter the fuel system when the
following events occur: NOTICE
Do not crank the engine continuously for more than
• The fuel tank is empty or the fuel tank has been 30 seconds. Allow the starting motor to cool for two
partially drained. minutes before cranking the engine again.

• The low pressure fuel lines are disconnected.

5. Observe the connection at the flare nut. Operate
• A leak exists in the low pressure fuel system. the starting motor and crank the engine until the
fuel is free of air.
• The fuel filter is replaced.
6. Tighten the flare nuts (1) to a torque of 30 N·m
• A new injection pump is installed. (22 lb ft).

Use the following procedure in order to remove air 7. The engine is now ready to start. Operate the
from the fuel system: engine at low idle for a minimum of five minutes
immediately after air has been removed from the
1. Remove the cover for the fuel injectors. Refer to fuel system.
the Disassembly and Assembly Manual.
Note: Running the engine for this period of time will
2. Turn the key switch to the RUN position. Leave help ensure that the pump is completely free of air.
the key switch in the RUN position for three
minutes.

3. Turn the key switch to the OFF position.

62
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

i01907680 i01907681

Fuel System Primary Fuel System Primary

Filter/Water Separator - Drain Filter/Water Separator Element
- Replace

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
changing fuel filters or water separator elements.
vent possible injury, turn the start switch off when
Clean up fuel spills immediately.
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
The water separator is not a filter. The water separa-
NOTICE
tor separates water from the fuel. The engine should
never be allowed to run with the water separator more Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
than half full. Engine damage may result.
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
The fuel filter/water separator (if equipped) is not
usually supplied by Perkins. The following text
The fuel filter/water separator (if equipped) is not
describes a typical fuel filter/water separator. Refer
usually supplied by Perkins. The following text
to the OEM information for further information on the
describes a typical fuel filter/water separator. Refer
fuel filter/water separator.
to the OEM information for further information on the
fuel filter/water separator.

Turn the fuel supply valve (if equipped) to the

OFF position before performing this maintenance.
Place a tray under the fuel filter in order to catch
any fuel that might spill. Clean up any spilled fuel
immediately.

g00741109
Illustration 36
(1) Cap
(2) Locking ring
(3) Element
(4) Water separator bowl
(5) Drain

1. Open drain (5). Catch the draining water in a

suitable container. Dispose of the drained water g00802952
Illustration 37
properly. (1) Cap
(2) Fuel filter base
2. Close drain (5). (3) Quick release collar
(4) Fuel filter
(5) Drain valve for fuel filter
NOTICE
The water separator is under suction during normal 1. Close the fuel supply valve (if equipped).
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
system.
 63
Maintenance Section
Fuel System Secondary Filter - Replace

2. Clean the outside of the fuel filter assembly. i01929325

Open drain valve (5) and drain the fuel and water
from fuel filter (4) into a suitable container. Fuel System Secondary Filter -
Note: If the fuel filter element is not equipped with
Replace
a drain, remove cap (1). Remove the nylon insert
in order to reduce the level of fuel in the fuel filter
element. A reduction in the level of fuel in the
fuel filter element will help prevent fuel from being
spilled when the element is removed.
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
NOTICE vent possible injury, turn the start switch off when
Do not use a tool in order to remove the fuel filter. changing fuel filters or water separator elements.
Attempting to remove the fuel filter with a filter wrench Clean up fuel spills immediately.
or a filter strap could damage the locking ring.

NOTICE
3. Hold fuel filter (4) and rotate quick release collar
Do not allow dirt to enter the fuel system. Thoroughly
(3) counterclockwise. Remove quick release
clean the area around a fuel system component that
collar (3). The used element should be removed will be disconnected. Fit a suitable cover over discon-
and discarded.
nected fuel system component.
Note: If the element is equipped with a sediment
bowl, remove the sediment bowl from the element. Turn the valves for the fuel lines (if equipped) to the
Thoroughly clean the sediment bowl. Inspect the OFF position before performing this maintenance.
O-ring seals. Install new O-ring seals, if necessary. Place a tray under the fuel filter in order to catch
Install the sediment bowl to the new element. Hand any fuel that might spill. Clean up any spilled fuel
tighten the sediment bowl. Hand tightening is the immediately.
only method that should be used.

NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.

4. Ensure that the fuel filter base is clean. Push a

new fuel filter fully into the fuel filter base.

5. Hold the fuel filter in place. Fit locking ring (3)

into position. Rotate the locking ring clockwise in
order to fasten the fuel filter to the fuel filter base.

Note: If the nylon insert was removed, install the

nylon insert and install cap (1).

6. Open the fuel supply valve (if equipped).

7. Prime the fuel system. Refer to the Operation

and Maintenance Manual, “Fuel System - Prime” g01010637
Illustration 38
for more information.
(1) Drain plug
(2) Filter bowl

1. Close the valves for the fuel lines (if equipped).

2. Clean the outside of the fuel filter assembly.

Open drain valve (1) and drain the fuel into a
suitable container.
64
Maintenance Section
Hoses and Clamps - Inspect/Replace

i01930349

Hoses and Clamps -

Inspect/Replace

Inspect all hoses for leaks that are caused by the

following conditions:

• Cracking
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.

NOTICE
g01010595 Do not bend or strike high pressure lines. Do not in-
Illustration 39
stall bent or damaged lines, tubes or hoses. Repair
(3) O ring seal any loose or damaged fuel and oil lines, tubes and
(4) Element
(5) Filter head
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
3. Remove the filter bowl (2) from the filter head ommended torque.
(5). Press on the element (4). Rotate the element
counterclockwise in order to release the element Check for the following conditions:
for the filter bowl and remove the element from
the bowl. Discard the used element. • End fittings that are damaged or leaking
4. Remove the O ring (3) from the filter bowl and • Outer covering that is chafed or cut
clean the filter bowl. Check that the threads of
the filter bowl are not damaged. • Exposed wire that is used for reinforcement
5. Install a new O ring seal (3) to the filter bowl (2). • Outer covering that is ballooning locally
6. Locate a new filter element (4) into the filter bowl. • Flexible part of the hose that is kinked or crushed
Press on the element and rotate the element
clockwise in order to lock the element into the • Armoring that is embedded in the outer covering
filter bowl.
A constant torque hose clamp can be used in
7. Install the filter bowl (4) into the top of the filter place of any standard hose clamp. Ensure that the
head (5). constant torque hose clamp is the same size as
the standard clamp.
8. Tighten the filter bowl by hand until the filter bowl
contacts the filter head. Rotate the filter bowl Due to extreme temperature changes, the hose
through 90 degrees. will harden. Hardening of the hoses will cause
hose clamps to loosen. This can result in leaks. A
Note: Do not use a tool to tighten the filter bowl. constant torque hose clamp will help to prevent
loose hose clamps.
9. Open the valves for the fuel lines (if equipped).
Each installation application can be different. The
10. Prime the fuel system. Refer to Operation and differences depend on the following factors:
Maintenance Manual, “Fuel System - Prime”.
• Type of hose
• Type of fitting material
 65
Maintenance Section
Radiator - Clean

• Anticipated expansion and contraction of the Note: For the proper coolant, see Operation and
hose Maintenance Manual, “General Coolant Information
and Coolant Recommendations”.
• Anticipated expansion and contraction of the
fittings 8. Refill the cooling system. Refer to the OEM
information for further information on refilling the
Replace the Hoses and the Clamps cooling system.

9. Clean the cooling system filler cap. Inspect

Refer to the Torque Specifications Manual for further
information on pipe fittings, hose clamps, and the cooling system filler cap’s seals. Replace
the cooling system filler cap if the seals are
constant torque hose clamps.
damaged. Install the cooling system filler cap.
Refer to the OEM information for further information
10. Start the engine. Inspect the cooling system for
on removing and replacing fuel hoses (if equipped).
leaks.
The coolant system and the hoses for the coolant
system are not usually supplied by Perkins. i01907732
The following text describes a typical method
of replacing coolant hoses. Refer to the OEM Radiator - Clean
information for further information on the coolant
system and the hoses for the coolant system.

The radiator is not usually supplied by Perkins.

The following text describes a typical cleaning
procedure for the radiator. Refer to the OEM
Pressurized System: Hot coolant can cause seri- information for further information on cleaning the
ous burns. To open the cooling system filler cap, radiator.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Note: Adjust the frequency of cleaning according to
pressure cap slowly in order to relieve the pres- the effects of the operating environment.
sure.
Inspect the radiator for these items: Damaged fins,
1. Stop the engine. Allow the engine to cool. corrosion, dirt, grease, insects, leaves, oil, and
other debris. Clean the radiator, if necessary.
2. Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap.
Personal injury can result from air pressure.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused. Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
3. Drain the coolant from the cooling system to tective face shield and protective clothing.
a level that is below the hose that is being
replaced. Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
4. Remove the hose clamps.

5. Disconnect the old hose. Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
6. Replace the old hose with a new hose. to the fan’s air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the radiator fins. Slowly
Note: For torques on hose clamps, see Torque move the air nozzle in a direction that is parallel
Specifications Manual, “Torques for Standard Hose with the radiator tube assembly. This will remove
Clamps and Torques for Constant Torque Hose debris that is between the tubes.
Clamps”. Also refer to the OEM information for
further information on torques for hose clamps. Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
7. Install the hose clamps with a torque wrench. must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
66
Maintenance Section
Severe Service Application - Check

Use a degreaser and steam for removal of oil and Due to individual applications, it is not possible
grease. Clean both sides of the core. Wash the core to identify all of the factors which can contribute
with detergent and hot water. Thoroughly rinse the to severe service operation. Consult your Perkins
core with clean water. dealer or your Perkins distributor for the unique
maintenance that is necessary for the engine.
If the radiator is blocked internally, refer to the
OEM Manual for information regarding flushing the The operating environment, improper operating
cooling system. procedures and improper maintenance procedures
can be factors which contribute to a severe service
After cleaning, start the engine and accelerate application.
the engine to high idle rpm. This will help in the
removal of debris and the drying of the core. Stop
the engine. Use a light bulb behind the core in
Environmental Factors
order to inspect the core for cleanliness. Repeat
Ambient temperatures – The engine may be
the cleaning, if necessary.
exposed to extended operation in extremely
cold environments or hot environments. Valve
Inspect the fins for damage. Bent fins may be
components can be damaged by carbon buildup if
opened with a “comb”. Inspect these items for
the engine is frequently started and stopped in very
good condition: Welds, mounting brackets, air lines, cold temperatures. Extremely hot intake air reduces
connections, clamps, and seals. Make repairs, if
engine performance.
necessary.
Quality of the air – The engine may be exposed to
i01907735 extended operation in an environment that is dirty
or dusty, unless the equipment is cleaned regularly.
Severe Service Application - Mud, dirt and dust can encase components.
Check Maintenance can be very difficult. The buildup can
contain corrosive chemicals.

Buildup – Compounds, elements, corrosive

chemicals and salt can damage some components.
Severe service is the application of an engine
that exceeds the current published standards for
Altitude – Problems can arise when the engine
that engine. Perkins maintains standards for the
is operated at altitudes that are higher than the
following engine parameters:
intended settings for that application. Necessary
adjustments should be made.
• Performance such as power range, speed range,
and fuel consumption
Improper Operating Procedures
• Fuel quality
• Extended operation at low idle
• Operational Altitude
• Frequent hot shutdowns
• Maintenance intervals
• Operating at excessive loads
• Oil selection and maintenance
• Operating at excessive speeds
• Coolant type and maintenance
• Operating outside the intended application
• Environmental qualities
Improper Maintenance Procedures
• Installation
Refer to the standards for the engine or consult • Extending the maintenance intervals
your Perkins dealer or your Perkins distributor in
order to determine if the engine is operating within • Failure to use recommended fuel, lubricants and
coolant/antifreeze
the defined parameters.

Severe service operation can accelerate component

wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention
of full service life.
 67
Maintenance Section
Starting Motor - Inspect

i01907746 A visual inspection of the turbocharger can minimize

unscheduled downtime. A visual inspection of
Starting Motor - Inspect the turbocharger can also reduce the chance for
potential damage to other engine parts.

Perkins recommends a scheduled inspection of the Removal and Installation

starting motor. If the starting motor fails, the engine
may not start in an emergency situation. Note: The turbochargers that are supplied are
nonserviceable.
Check the starting motor for proper operation.
Check the electrical connections and clean the For options regarding the removal, installation, and
electrical connections. Refer to the Systems replacement, consult your Perkins dealer or your
Operation, Testing and Adjusting Manual, “Electric Perkins distributor. Refer to the Disassembly and
Starting System - Test” for more information on Assembly Manual, “Turbocharger - Remove and
the checking procedure and for specifications Turbocharger - Install” for further information.
or consult your Perkins dealer or your Perkins
distributor for assistance. Inspecting
i01929801 NOTICE
The compressor housing for the turbocharger must
Turbocharger - Inspect not be removed from the turbocharger for cleaning.

The actuator linkage is connected to the compressor

housing. If the actuator linkage is moved or disturbed
A regular visual inspection of the turbocharger the engine may not comply with emmissions legisla-
is recommended. Any fumes from the crankcase tion.
are filtered through the air inlet system. Therefore,
by-products from oil and from combustion can
collect in the turbocharger compressor housing. 1. Remove the pipe from the turbocharger exhaust
Over time, this buildup can contribute to loss of outlet and remove the air intake pipe to the
engine power, increased black smoke and overall turbocharger. Visually inspect the piping for the
loss of engine efficiency. presence of oil. Clean the interior of the pipes
in order to prevent dirt from entering during
If the turbocharger fails during engine operation, reassembly.
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to 2. Check for the presence of oil. If oil is leaking from
the turbocharger compressor wheel can cause the back side of the compressor wheel, there is
additional damage to the pistons, the valves, and a possibility of a failed turbocharger oil seal.
the cylinder head.
The presence of oil may be the result of extended
engine operation at low idle. The presence of
NOTICE oil may also be the result of a restriction of the
Turbocharger bearing failures can cause large quanti- line for the intake air (clogged air filters), which
ties of oil to enter the air intake and exhaust systems. causes the turbocharger to slobber.
Loss of engine lubricant can result in serious engine
damage. 3. Inspect the bore of the housing of the turbine
outlet for corrosion.
Minor leakage of oil into a turbocharger under extend-
ed low idle operation should not cause problems as 4. Fasten the air intake pipe and the exhaust outlet
long as a turbocharger bearing failure has not oc- pipe to the turbocharger housing.
cured.

When a turbocharger bearing failure is accompanied

by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is renewed.
68
Maintenance Section
Walk-Around Inspection

i01907741 Excessive coolant leakage may indicate the need

to replace the water pump seal. For the removal of
Walk-Around Inspection the water pump and the installation of water pump
and/or seal, refer to the Disassembly and Assembly
Manual, “Water Pump - Remove and Install” for
more information or consult your Perkins dealer or
Inspect the Engine for Leaks and your Perkins distributor.
for Loose Connections • Inspect the lubrication system for leaks at the
front crankshaft seal, the rear crankshaft seal, the
A walk-around inspection should only take a few oil pan, the oil filters and the rocker cover.
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be
avoided.
• Inspect the fuel system for leaks. Look for loose
fuel line clamps and/or tie-wraps.
For maximum engine service life, make a thorough
inspection of the engine compartment before
• Inspect the piping for the air intake system and
the elbows for cracks and for loose clamps.
starting the engine. Look for items such as oil leaks Ensure that hoses and tubes are not contacting
or coolant leaks, loose bolts, worn belts, loose other hoses, tubes, wiring harnesses, etc.
connections and trash buildup. Make repairs, as
needed:
• Inspect the alternator belts and any accessory
drive belts for cracks, breaks or other damage.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards. Belts for multiple groove pulleys must be replaced
as matched sets. If only one belt is replaced, the
• Wipe all caps and plugs before the engine is belt will carry more load than the belts that are
serviced in order to reduce the chance of system not replaced. The older belts are stretched. The
contamination. additional load on the new belt could cause the
belt to break.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the • Drain the water and the sediment from the fuel
fluid. If leaking is observed, find the source and correct tank on a daily basis in order to ensure that only
the leak. If leaking is suspected, check the fluid levels clean fuel enters the fuel system.
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be • Inspect the wiring and the wiring harnesses for
unwarranted. loose connections and for worn wires or frayed
wires.
NOTICE
Accumulated grease and/or oil on an engine is a fire • Inspect the ground strap for a good connection
and for good condition.
hazard. Remove the accumulated grease and oil. Re-
fer to this Operation and Maintenance Manual, “En-
gine - Clean” for more information. • Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte
• Ensure that the cooling system hoses are properly level of the batteries, unless the engine is
clamped and that the cooling system hoses are equipped with a maintenance free battery.
tight. Check for leaks. Check the condition of all
pipes. • Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that
• Inspect the water pump for coolant leaks. can not be calibrated.

Note: The water pump seal is lubricated by the

i01907756
coolant in the cooling system. It is normal for a
small amount of leakage to occur as the engine Water Pump - Inspect
cools down and the parts contract.

A failed water pump may cause severe engine

overheating problems that could result in the
following conditions:
 69
Maintenance Section
Water Pump - Inspect

• Cracks in the cylinder head

• A piston seizure
• Other potential damage to the engine
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. Renew

the water pump seal or the water pump if there
is an excessive leakage of coolant. Refer to the
Disassembly and Assembly Manual, “Water Pump
- Remove and Install” for the disassembly and
assembly procedure.
70
Warranty Section
Warranty Information

Warranty Section

Warranty Information
i01903596

Emissions Warranty
Information

This engine may be certified to comply with

exhaust emission standards and gaseous emission
standards that are prescribed by the law at the
time of manufacture, and this engine may be
covered by an Emissions Warranty. Consult your
authorized Perkins dealer or your authorized Perkins
distributor in order to determine if your engine is
emissions certified and if your engine is subject to
an Emissions Warranty.
 71
Index Section

Index
A Engine - Clean....................................................... 52
Engine Air Cleaner Element (Dual Element) -
After Starting Engine ............................................. 27 Clean/Replace ..................................................... 53
After Stopping Engine............................................ 29 Cleaning the Primary Air Cleaner Elements ...... 54
Aftercooler Core - Clean/Test ................................ 47 Servicing the Air Cleaner Elements ................... 53
Aftercooler Core - Inspect...................................... 47 Engine Air Cleaner Element (Single Element) -
Aftermarket Oil Additives ....................................... 37 Replace................................................................ 55
Alternator - Inspect ................................................ 48 Engine Air Cleaner Service Indicator - Inspect...... 55
Alternator and Fan Belts - Inspect/Adjust/ Test the Service Indicator .................................. 56
Replace................................................................ 48 Engine Description ................................................ 16
Adjustment ......................................................... 48 Engine Cooling and Lubrication......................... 17
Inspection........................................................... 48 Engine Service Life ............................................ 18
Replacement...................................................... 48 Engine Specifications......................................... 16
Engine Ground - Inspect/Clean ............................. 56
Engine Identification .............................................. 19
B Engine Lifting......................................................... 21
Engine Mounts - Inspect........................................ 56
Battery - Replace................................................... 49 Engine Oil .............................................................. 34
Battery Electrolyte Level - Check .......................... 49 Commercial Oils................................................. 34
Battery or Battery Cable - Disconnect ................... 50 Total Base Number (TBN) and Fuel Sulfur Levels
Before Starting Engine .................................... 10, 25 for Direct Injection (DI) Diesel Engines ............ 35
Burn Prevention....................................................... 8 Engine Oil and Filter - Change .............................. 57
Batteries............................................................... 8 Drain the Engine Oil........................................... 58
Coolant................................................................. 8 Fill the Engine Crankcase .................................. 59
Oils....................................................................... 8 Replace the Element for the Oil Filter ................ 59
Replace the Spin-on Oil Filter ........................... 58
Engine Oil Level - Check ....................................... 56
C Engine Oil Sample - Obtain ................................... 57
Obtain the Sample and the Analysis.................. 57
Cold Weather Lubricants ....................................... 37 Engine Operation................................................... 28
Cold Weather Operation ........................................ 30 Engine Starting................................................ 11, 25
Hints for Cold Weather Operation ...................... 30 Engine Stopping .............................................. 11, 29
Idling the Engine ................................................ 31 Engine Storage...................................................... 21
Recommendations for Coolant Warm Up .......... 31 Cooling System.................................................. 22
Recommendations for the Coolant .................... 30 Exhaust System ................................................. 22
Viscosity of the Engine Lubrication Oil .............. 30 General Items .................................................... 23
Cold Weather Starting ........................................... 26 Induction System ............................................... 22
Coolant Recommendations ................................... 43 Lubrication System ............................................ 21
Cooling System Coolant - Change ........................ 50 Engine Valve Lash - Inspect/Adjust ....................... 60
Cooling System Coolant - Test/Add....................... 51 Engine Warm-up.................................................... 28
Check the specific gravity of the coolant............ 51
Cooling System Coolant Level - Check ................. 51
Cooling System Specifications .............................. 42 F
Crushing Prevention and Cutting Prevention......... 10
Fire Prevention and Explosion Prevention............... 8
Fire Extinguisher .................................................. 9
D Lines, Tubes and Hoses..................................... 10
Foreword.................................................................. 5
Driven Equipment - Check..................................... 52 California Proposition 65 Warning ....................... 5
Literature Information........................................... 4
Maintenance ........................................................ 4
E Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Electrical System................................................... 11 Overhaul .............................................................. 4
Grounding Practices .......................................... 12 Safety................................................................... 4
Emergency Stopping ............................................. 29 Fuel and the Effect from Cold Weather ................. 32
Emissions Certification Film .................................. 19 Fuel Conservation Practices.................................. 28
Emissions Warranty Information............................ 70
72
Index Section

Fuel Injector - Test/Change ................................... 60 O

Removal and Installation of the Fuel Injectors ... 60
Fuel Recommendations......................................... 39 Operation Section.................................................. 21
Fuel Related Components in Cold Weather .......... 33
Fuel Filters ......................................................... 33
Fuel Heaters ...................................................... 33 P
Fuel Tanks.......................................................... 33
Fuel Specifications ................................................ 39 Product Identification Information .......................... 19
Fuel System - Prime.............................................. 61 Product Information Section .................................. 13
Fuel System Primary Filter/Water Separator -
Drain .................................................................... 62
Fuel System Primary Filter/Water Separator Element R
- Replace ............................................................. 62
Fuel System Secondary Filter - Replace............... 63 Radiator - Clean .................................................... 65
Re-refined Base Stock Oils ................................... 37
Reference Numbers .............................................. 19
G Record for Reference......................................... 19
Refill Capacities..................................................... 44
Gauges and Indicators .......................................... 24 Cooling System.................................................. 44
General Coolant Information ................................. 42 Lubrication System ............................................ 44
Additives ............................................................ 42
Glycol ................................................................. 43
Water ................................................................. 42 S
General Hazard Information .................................... 6
Containing Fluid Spillage ..................................... 7 S·O·S Oil Analysis ................................................. 38
Fluid Penetration .................................................. 7 Safety Section ......................................................... 6
Pressure Air and Water........................................ 7 Safety Signs and Labels.......................................... 6
Serial Number Plate .............................................. 19
Severe Service Application - Check ...................... 66
H Environmental Factors ....................................... 66
Improper Maintenance Procedures.................... 66
Hoses and Clamps - Inspect/Replace ................... 64 Improper Operating Procedures ........................ 66
Replace the Hoses and the Clamps .................. 65 Starting Motor - Inspect ......................................... 67
Starting the Engine................................................ 25
Starting with Jump Start Cables ............................ 27
I Stopping the Engine .............................................. 29
Synthetic Base Stock Oils ..................................... 36
Important Safety Information ................................... 2

T
L
Table of Contents..................................................... 3
Lifting and Storage ................................................ 21 Turbocharger - Inspect........................................... 67
Lubricant Information............................................. 34 Inspecting........................................................... 67
API Oils .............................................................. 34 Removal and Installation.................................... 67
Engine Manufacturers Association (EMA) Oils .. 34
General Information ........................................... 34
Lubricant Specifications ........................................ 34 W

Walk-Around Inspection ........................................ 68

M Inspect the Engine for Leaks and for Loose
Connections ..................................................... 68
Maintenance Interval Schedule ............................. 46 Warranty Information ............................................. 70
Maintenance Section ............................................. 34 Warranty Section ................................................... 70
Model View Illustrations......................................... 13 Water Pump - Inspect............................................ 68
1103 Engine Model Views ................................. 15
1104 Engine Model Views ................................. 13
Model Views .......................................................... 13
Mounting and Dismounting.................................... 10