№82 Руководство по ремонту. Двигатель perkins 800 series

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure toobserve basic safety rules or precautions. An accident can often be avoided by recognizing potentiallyhazardous situations before an accident occurs. A person must be alert to potential hazards. Thisperson 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 andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazardwarnings 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 asDANGER, 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 orpictorially presented.

Operations that may cause product damage are identified by NOTICE labels on the product and inthis publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. Thewarnings 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 theproduct will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information beforeyou start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for thisproduct Perkins recommends using Perkins

replacement parts.Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

AndreP

3Table of Contents

Table of ContentsForeword ................................................................. 4

Safety SectionSafety Signs and Labels ......................................... 6

General Hazard Information ................................... 8

Burn Prevention ...................................................... 9

Fire Prevention and Explosion Prevention ............ 10

Crushing Prevention and Cutting Prevention ........ 12

Before Starting Engine .......................................... 12

Engine Starting ..................................................... 12

Engine Stopping ................................................... 13

Electrical System .................................................. 13

Product Information SectionModel Views ......................................................... 14

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

Operation SectionLifting and Storage ................................................ 21

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

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

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

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

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

Maintenance SectionLubricant Specifications ........................................ 34

Fuel Specifications ................................................ 38

Cooling System Specifications ............................. 41

Refill Capacities .................................................... 47

Maintenance Interval Schedule ............................ 48

Warranty SectionWarranty Information ............................................ 69

Index SectionIndex ..................................................................... 70

4Foreword

Foreword

Literature Information

This manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literatur e holder or literatur e storage area. Read,study and keep it with the literatur e and engineinformation.

English is the prima ry language for all Perkinspublications. The English used facilitates translationand consistency in electr onic media deliver y.

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Perkins dealer or your Perkins distributor for the latest available information.

Safety

This safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or per forming lubrication, maintenanceand repair on this product.

Operation

Operating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques requir ed to operate the engine moreefficiently and economically . Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting,operating and stopping the engine.

Maintenance

The maintenance section is a guide to enginecare. The illustrated, step-by-step instructions aregrouped by service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.

Recommended service should be per formedat the appropriate intervals as indicated inthe Maintenance Interval Schedule. The actualoperating envir onment of the engine also gover nsthe Maintenance Interval Schedule. Therefore,under extremely severe, dusty, wet or freezing coldoperating conditions, more frequent lubrication andmaintenance than is specified in the MaintenanceInterval Schedule may be necessar y.

The maintenance schedule items are organizedfor a preventive maintenance managementprogram. If the preventive maintenance programis followed, a periodic tune-up is not requir ed.The implementation of a preventive maintenancemanagement program should minimize operatingcosts through cost avoidances resulting fromreductions in unscheduled downtime and failur es.

Maintenance Intervals

Perform maintenance on items at multiplesof the original requi rement. We recommend that the maintenance schedulesbe reproduced and displayed near the engine asa convenient reminder. We also recommend that amaintenance record be maintained as part of theengines permanent record.

Your authorized Perkins dealer or your Perkinsdistributor can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating envir onment.

Overhaul

Major engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs should only be carried out by Perkins authorized per sonnel . Your Perkins dealer oryour Perkins distributor offer a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available .Consult your Perkins dealer or your Perkins distributor for information regarding these options.

5Foreword

California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

6Safety SectionSafety Signs and Labels

Safety Sectioni01933317

Safety Signs and Labels

There may be several specific warning signs onan engine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiar with all warningsigns.

Ensure that all of the warning signs are legible.Clean the warning signs or replace the warningsigns if the words cannot be read or if the picturesare not visible. When the warning signs arecleaned, use a cloth, water, and soap. Do not usesolvent, gasoline, or other harsh chemicals to cleanthe warning signs. Solvents, gasoline, or harshchemicals could loosen the adhesive that securesthe warning signs. The warning signs that areloosened could drop off of the engine.

Replace any damaged warning signs or missingwarning signs. If a warning sign is attached to apart of the engine that is replaced, install a newwarning sign on the replacement part. Any Perkinsdealer or any Perkins distributor can provide newwarning signs.

Do not work on the engine and do not operate theengine unless the instructions and warnings in theOperation and Maintenance Manual are understood.Proper care is your responsibility. Failure to followthe instructions or failure to heed the warningscould result in injury or in death.

The warning labels that may be found on the engineare illustrated and described.

7Safety Section

Safety Signs and Labels

g01000440Illustration 1

8Safety SectionGeneral Hazard Information

Do Not Operate Before Reading theManual (1)This message is located on the side of the valvecover.

g00934493

Do not operate or work on this engine unless youhave read and understand the instructions andwarnings in the Operation and Maintenance Man-ual. Failure to follow the instructions or heed thewarnings could result in injury or death. Contactany Perkins dealer for replacement manuals.Proper care is your responsibility.

Starting Aid (2)The warning label for the starting aid is located ontop of the air inlet manifold.

g00283559

If equipped with an air inlet heater (AIH) for coldweather starting, do not use aerosal types of start-ing aids such as ether. Such use could result in anexplosion and personal injury.

i01884947

General Hazard Information


Attach a Do Not Operate warning tag or a similarwarning tag to the start switch or to the controlsbefore you service the equipment or before yourepair the equipment.


Wear a hard hat, protective glasses, and otherprotective equipment, as required.

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine.

Make sure that all protective guards and all coversare secured in place on the engine.

Keep the engine free from foreign material. Removedebris, 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.

9Safety Section

Burn Prevention

Use all cleaning solutions with care. Report allnecessary repairs.

Do not allow unauthorized personnel on theequipment.

Unless you are instructed otherwise, performmaintenance on the engine with the equipment inthe servicing position. Refer to the OEM informationfor the procedure for placing the equipment in theservicing position.

Pressure Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could resultin personal injury.

When pressurized air and/or water is used forcleaning, wear protective clothing, protective shoes,and eye protection. Eye protection includes gogglesor a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must bebelow 275 kPa (40 psi).

Fluid PenetrationPressure can be trapped in the hydraulic circuitlong after the engine has been stopped. Thepressure can cause hydraulic fluid or items suchas pipe plugs to escape rapidly if the pressure isnot relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has beenrelieved or personal injury may occur. Refer tothe OEM information for any procedures that arerequired to relieve the hydraulic pressure.


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leakcan cause severe injury. If fluid is injected into yourskin, you must get treatment immediately. Seektreatment from a doctor that is familiar with this typeof injury.

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theengine. Make provision to collect the fluid witha suitable container before any compartment isopened or before any component is disassembled.

Only use the tools that are suitable for collectingfluids and equipment that is suitable for collectingfluids.

Only use the tools that are suitable for containingfluids and equipment that is suitable for containingfluids.

Obey all local regulations for the disposal of liquids.

i01480768

Burn Prevention

Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steamcan cause severe burns. Allow cooling systemcomponents to cool before the cooling system isdrained.

Check the coolant level after the engine hasstopped and the engine has been allowed to cool.

10Safety SectionFire Prevention and Explosion Prevention

Ensure that the filler cap is cool before removingthe filler cap. The filler cap must be cool enoughto touch with a bare hand. Remove the filler capslowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkalican cause personal injury. Do not allow alkali tocontact the skin, the eyes, or the mouth.

OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

BatteriesElectrolyte is an acid. Electrolyte can causepersonal injury. Do not allow electrolyte to contactthe skin or the eyes. Always wear protective glassesfor servicing batteries. Wash hands after touchingthe batteries and connectors. Use of gloves isrecommended.

i01885715

Fire Prevention and ExplosionPrevention


All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.

Determine whether the engine will be operated inan environment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.

If the application involves the presence ofcombustible gases, consult your Perkins dealerand/or your Perkins distributor for additionalinformation about suitable protection devices.

Remove all flammable materials such as fuel, oil,and debris from the engine. Do not allow anyflammable materials to accumulate on the engine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in case of a line,a tube, or a seal failure. Exhaust shields must beinstalled correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding or flame cutting.

Wiring must be kept in good condition. All electricalwires must be properly routed and securelyattached. Check all electrical wires daily. Repair anywires that are loose or frayed before you operatethe engine. Clean all electrical connections andtighten all electrical connections.

Eliminate all wiring that is unattached orunnecessary. Do not use any wires or cables thatare smaller than the recommended gauge. Do notbypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.

Oil filters and fuel filters must be properly installed.The filter housings must be tightened to the propertorque.

11Safety Section

Fire Prevention and Explosion Prevention


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Donot refuel an engine near open flames or sparks.Always stop the engine before refueling.


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may causean explosion.

The batteries must be kept clean. The covers (ifequipped) must be kept on the cells. Use therecommended cables, connections, and batterybox covers when the engine is operated.

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Perkins dealer forrepair or for replacement parts.

Check lines, tubes and hoses carefully. Do notuse your bare hand to check for leaks. Use aboard or cardboard to check for leaks. Tighten allconnections to the recommended torque.

Replace the parts if any of the following conditionsare present:

End fittings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are ballooning.

Flexible part of the hoses are kinked.

Outer covers have embedded armoring.

End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

12Safety SectionCrushing Prevention and Cutting Prevention

i01359666

Crushing Prevention andCutting Prevention

Support the component properly when workbeneath the component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

Stay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.

Keep objects away from moving fan blades. Thefan blades will throw objects or cut objects.

When objects are struck, wear protective glasses inorder to avoid injury to the eyes.

Chips or other debris may fly off objects whenobjects are struck. Before objects are struck, ensurethat no one will be injured by flying debris.

i01805780

Before Starting Engine

NOTICEFor initial start-up of a new or rebuilt engine, and forstart-up of an engine that has been serviced, makeprovision to shut the engine off should an overspeedoccur. This may be accomplished by shutting off theair and/or fuel supply to the engine.

Overspeed shutdown should occur automatically.If automatic shutdown does not occur, press theemergency stop button in order to cut the fueland/or air to the engine.

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. Ensure that thearea is free of personnel.

If equipped, ensure that the lighting system for theengine is suitable for the conditions. Ensure that alllights work properly, if equipped.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuitsare provided in order to help prevent personalinjury. The circuits are also provided in order to helpprevent engine damage.

See the Service Manual for repairs and foradjustments.

i01933350

Engine Starting

Do not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal injury.

If a warning tag is attached to the engine startswitch or to the controls, DO NOT start the engineor move the controls. Consult with the person thatattached the warning tag before the engine isstarted.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operators compartment orfrom the engine start switch.

Always start the engine according to the procedurethat is described in the Operation and MaintenanceManual, Engine Starting topic in the OperationSection. Knowing the correct procedure will help toprevent major damage to the engine components.Knowing the procedure will also help to preventpersonal injury.

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingproperly, check the water temperature gaugeand the oil temperature gauge during the heateroperation.

13Safety Section

Engine Stopping

Engine exhaust contains products of combustionwhich can be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is started in an enclosed area,vent the engine exhaust to the outside.

Note: The engine is equipped with an automaticdevice for cold starting for normal conditions ofoperation. If the engine will be operated in verycold conditions, then an extra cold starting aid maybe required. Normally, the engine will be equippedwith the correct type of starting aid for your regionof operation.

The 800 Series engine is equipped with a glow plugstarting aid in each individual cylinder that heatsthe intake air in order to improve starting.

i01032808

Engine Stopping

To avoid overheating of the engine and acceleratedwear of the engine components, stop the engineaccording to this Operation and MaintenanceManual, Engine Stopping topic (OperationSection).

Use the Emergency Stop Button (if equipped)ONLY in an emergency situation. DO NOT use theEmergency Stop Button for normal engine stopping.After an emergency stop, DO NOT start the engineuntil the problem that caused the emergency stophas been corrected.

On the initial start-up of a new engine or an enginethat has been serviced, make provisions to stop theengine if an overspeed condition occurs. This maybe accomplished by shutting off the fuel supplyand/or the air supply to the engine.

i01940471

Electrical System

Never disconnect any charging unit circuit or batterycircuit cable from the battery when the charging unitis operating. A spark can cause the combustiblegases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative jump start cable should be connectedlast from the external power source to the negative terminal of the starting motor. If the startingmotor is not equipped with a negative terminal,connect the jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. Seethe Operation and Maintenance Manual for specificstarting instructions.

Grounding PracticesProper grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Improper grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

To ensure that the engine and the engine electricalsystems function properly, an engine-to-frameground strap with a direct path to the battery mustbe used. This path may be provided by way of adirect engine ground to the frame.

All grounds should be tight and free of corrosion.The engine alternator must be grounded to thenegative - battery terminal with a wire that isadequate to handle the full charging current of thealternator.

14Product Information SectionModel Views

Product InformationSection

Model Viewsi01933688

Model View Illustrations


15Product Information Section

Model Views

Left side view of naturally aspirated 800 Series engineThis view is shown without one of the fuel injection nozzles for clarity.(1) Fan(2) Water pump(3) Oil filler(4) Fuel injection pump(5) Oil pressure switch

(6) Oil drain plug(7) Relief valve(8) Oil filter(9) Flywheel housing(10) Oil level gauge

(11) Water drain plug(12) Lifting eye(13) Oil filler cap(14) Glow plug(15) Fuel injection nozzle

g00988038Illustration 9Right side view of a naturally aspirated 800 Series engine(15) Exhaust manifold(16) Starter(17) Crankshaft vibration damper(18) V-Belt

(19) Alternator(20) Thermostat(21) Lifting eye(22) Oil filler cap


g00987267Illustration 10Left side view of turbocharged 800 Series engine(1) Oil cooler(2) Fan(3) Water pump(4) Oil filler(5) Fuel injection pump(6) Oil pressure switch(7) Oil drain plug(8) Relief valve

(9) Oil filter(10) Flywheel housing(11) Water drain plug(12) Oil level gauge(13) Crankcase breather(14) Inlet manifold(15) Glow plug(16) Fuel injection nozzle


Model Views

g00987270Illustration 11Right side view of turbocharged 800 Series engine(17) Lifting eye(18) Exhaust manifold(19) Starter

(20) Crankshaft vibration damper(21) V-Belt(22) Alternator

(23) Thermostat(24) Lifting eye(25) Turbocharger


i01933689

Engine Description

Table 1

Naturally Aspirated 800 Series SpecificationsType Four Stroke CycleNumber of Cylinders 4 In-LineBore 94 mm (3.70 inch)Stroke 120 mm (4.72 inch)Aspiration Naturally AspiratedCompression ratio 22:1Displacement 3.33 L (203 in3)Firing Order 1-3-4-2Rotation that is viewedfrom the flywheel Counterclockwise

Valve Lash Setting (Inlet) 0.25 mm (0.0098 inch)Valve Lash Setting(Exhaust) 0.25 mm (0.0098 inch)

Table 2

Turbocharged 800 Series SpecificationsType Four Stroke CycleNumber of Cylinders 4 In-LineBore 94 mm (3.70 inch)Stroke 120 mm (4.72 inch)Aspiration TurbochargedCompression ratio 19:1Displacement 3.33 L (203 in3)Firing Order 1-3-4-2Rotation that is viewedfrom the flywheel Counterclockwise

Valve Lash Setting (Inlet) 0.25 mm (0.0098 inch)Valve Lash Setting(Exhaust) 0.25 mm (0.0098 inch)

Engine Cooling and LubricationThe cooling system consists of the followingcomponents:

Gear-driven centrifugal water pump

Water temperature regulators which regulate theengine coolant temperature

Gear-driven oil pump (gear type)

Oil cooler

The engine lubricating oil is supplied by a geartype pump. The engine lubricating oil is cooledand the engine lubricating oil is filtered. Bypassvalves provide unrestricted flow of lubrication oilto the engine parts when oil viscosity is high.Bypass valves can also provide unrestricted flow oflubrication oil to the engine parts if the oil coolershould become plugged or if the oil filter elementshould become plugged.

Engine efficiency, efficiency of emissioncontrols, and engine performance depend onadherence to proper operation and maintenancerecommendations. Engine performance andefficiency also depend on the use of recommendedfuels, lubrication oils, and coolants. Refer to theOperation and Maintenance Manual, MaintenanceInterval Schedule for more information onmaintenance items.

Engine Service LifeEngine efficiency and maximum utilization of engineperformance depend on the adherence to properoperation and maintenance recommendations. Inaddition, use recommended fuels, coolants andlubricants. Use the Operation and MaintenanceManual as a guide for required engine maintenance.

Expected engine life is generally predictedby the average power that is demanded. Theaverage power that is demanded is based on fuelconsumption of the engine over a period of time.Reduced hours of operation at full throttle and/oroperating at reduced throttle settings result in alower average power demand. Reduced hours ofoperation will increase the length of operating timebefore an engine overhaul is required.


Product Identification Information

Product IdentificationInformation

i01933733

Engine Identification

Perkins engines are identified by a serial number.This number is shown on a serial number plate thatis mounted on the left hand side of the engine block.

An example of an engine number is UEU090001H.

UE _________________________________________Type of engine

U __________________________Built in the United Kingdom

0900001 ________________________Engine Serial Number

H ____________________________________Year of Manufacture

Perkins dealers need all of these numbers in orderto determine the components that were includedwith the engine. This permits accurate identificationof replacement part numbers.

i01933737

Serial Number Plate

g00994966Illustration 12Typical serial number plate(1) Temporary Parts List number(2) Type(3) Serial number(4) List number

The Serial Number Plate is located on the left sideof the cylinder block.

The following information is stamped on the SerialNumber Plate: Engine serial number, Model, andArrangement number.

i01892045

Reference Numbers

Information for the following items may be neededto order parts. Locate the information for yourengine. Record the information on the appropriatespace. Make a copy of this list for a record. Keepthe information for future reference.

Record for ReferenceEngine Model ______________________________________________

Engine Serial No. __________________________________________

Engine Low Idle rpm _____________________________________

Engine Full Load rpm ____________________________________

Primary Fuel Filter No. ___________________________________

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. ________________________________________

i01933748

Emissions Certification Film

A typical example is shown.

20Product Information SectionProduct Identification Information


21Operation Section

Lifting and Storage

Operation Section

Lifting and Storagei01898037

Engine Lifting


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) shouldbe parallel to each other. The chains and cablesshould be perpendicular to the top of the objectthat is being lifted.

Some removals require lifting the fixtures in order toobtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for specificengine arrangements. Alterations to the lifting eyesand/or the engine make the lifting eyes and thelifting fixtures obsolete. If alterations are made,ensure that proper lifting devices are provided.Consult your Perkins dealer for informationregarding fixtures for proper engine lifting.

i01942172

Engine Storage

If the engine will not be started for several weeks,the lubricating oil will drain from the cylinder wallsand from the piston rings. Rust can form on thecylinder walls. Rust on the cylinder walls will causeincreased engine wear and a reduction in engineservice life.

Lubrication SystemTo help prevent excessive engine wear, use thefollowing guidelines:

Complete all of the lubrication recommendationsthat are listed in this Operation and MaintenanceManual, Maintenance Interval Schedule(Maintenance Section).

If an engine is out of operation and if use of theengine is not planned, special precautions shouldbe made. If the engine will be stored for more thanone month, a complete protection procedure isrecommended.

Use the following guidelines :

Completely clean the outside of the engine.

Drain the fuel system completely and refillthe system with preservative fuel.1772204POWERPART Lay-Up 1 can be mixed with thenormal fuel in order to change the fuel intopreservative fuel.

If preservative fuel is not available, the fuel systemcan be filled with normal fuel. This fuel mustbe discarded at the end of the storage periodtogether with the fuel filter elements.

Operate the engine until the engine reachesnormal operating temperature. Stop any leaksfrom fuel, lubricating oil or air systems. Stop theengine and drain the lubricating oil from the oilpan.

Renew the canister(s) of the lubricating oil filter.

22Operation SectionLifting and Storage

Fill the oil pan to the Full Mark on the dipstickwith new, clean lubricating oil. Add 1762811POWERPART Lay-Up 2 to the oil in order toprotect the engine against corrosion. If 1762811POWERPART Lay-Up 2 is not available, use apreservative of the correct specification insteadof the lubricating oil. If a preservative is used,this must be drained completely at the end of thestorage period and the oil pan must be refilled tothe correct level with normal lubricating oil.

Cooling SystemTo help prevent excessive engine wear, use thefollowing guidelines:

NOTICEDo not drain the coolant while the engine is still hot andthe system is under pressure because dangerous hotcoolant can be discharged.

If freezing temperatures are expected, check thecooling system for adequate protection againstfreezing. See this Operation and MaintenanceManual, General Coolant Information (MaintenanceSection).

NOTICETo prevent frost damage, ensure that all the coolant isremoved from the engine. This is important if the sys-tem is drained after it has been flushed with water, or ifan antifreeze solution too weak to protect the systemfrom frost has been used.


1. Ensure that the vehicle is on level ground.

2. Remove the filler cap of the cooling system.

3. Remove the drain plug (1) from the side of thecylinder block in order to drain the engine.Ensure that the drain hole is not restricted.

4. Open the tap or remove the drain plug at thebottom of the radiator in order to drain theradiator. If the radiator does not have a tap or adrain plug, disconnect the hose at the bottomof the radiator.

5. Flush the cooling system with clean water.

6. Fit the drain plugs and the filler cap. Close thetap or connect the radiator hose.

7. Fill the cooling system with an approvedantifreeze mixture because this gives protectionagainst corrosion.

Note: Certain corrosion inhibitors could causedamage to some engine components. Contact theService Department of Perkins for advice.

8. Operate the engine for a short period in orderto circulate the lubricating oil and the coolantin the engine.

9. Disconnect the battery. Put the battery into safestorage in a fully charged condition. Before thebattery is put into storage, protect the terminalsagainst corrosion.1734115 POWERPART Lay-Up3 can be used on the terminals.

10. Clean the crankcase breather if one is installed.Seal the end of the pipe.

11. Remove the fuel injector nozzles and spray1762811 POWERPART Lay-Up 2 for one or twoseconds into each cylinder bore with the pistonat BDC.

12. Slowly rotate the crankshaft for one completerevolution and then replace the fuel injectornozzles.

Induction System Remove the air filter assembly. If necessary,

remove the pipes that are installed betweenthe air filter assembly and the turbocharger.Spray 1762811 POWERPART Lay-Up 2 into theturbocharger. The duration of the spray is printedon the container. Seal the turbocharger withwaterproof tape.

Exhaust System Remove the exhaust pipe. Spray 1762811

POWERPART Lay-Up 2 into the turbocharger. Theduration of the spray is printed on the container.Seal the turbocharger with waterproof tape.

23Operation Section

Lifting and Storage

General Items If the lubricating oil filler is installed on the rocker

cover, remove the filler cap. If the lubricatingoil filler cap is not installed on the rockercover, remove the rocker cover. Spray 1762811POWERPART Lay-Up 2 around the rocker shaftassembly. Replace the filler cap or the rockercover.

Seal the vent of the fuel tank or the fuel filler capwith waterproof tape.

Remove the alternator drive belts and put thedrive belts into storage.

In order to prevent corrosion, spray the enginewith 1734115 POWERPART Lay-Up 3. Do notspray the area inside the alternator.

When the engine protection has been completed inaccordance with these instructions, this ensures thatno corrosion will occur. Perkins are not responsiblefor damage which may occur when an engine is instorage after a period in service.

Your Perkins dealer or your Perkins distributor canassist in preparing the engine for extended storageperiods.

24Operation SectionGauges and Indicators

Gauges and Indicatorsi01930356

Gauges and Indicators

Your engine may not have the same gauges or all ofthe gauges that are described. For more informationabout the gauge package, see the OEM information.

Gauges provide indications of engine performance.Ensure that the gauges are in good working order.Determine the normal operating range by observingthe gauges over a period of time.

Noticeable changes in gauge readings indicatepotential gauge or engine problems. Problems mayalso be indicated by gauge readings that changeeven if the readings are within specifications.Determine and correct the cause of any significantchange in the readings. Consult your Perkins dealeror your Perkins distributor for assistance.

NOTICEIf no oil pressure is indicated, STOP the engine. Ifmaximum coolant temperature is exceeded, STOP theengine. Engine damage can result.

Engine Oil Pressure The oil pressureshould be greatest after a cold engine isstarted. The typical engine oil pressure

with SAE10W30 is 207 to 413 kPa (30 to 60 psi) atrated rpm.

A lower oil pressure is normal at low idle. If the loadis stable and the gauge reading changes, performthe 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 at48 kPa (7 psi) is 110C (230F). Higher temperaturesmay occur under certain conditions. The watertemperature reading may vary according to load.The reading should never exceed the boiling pointfor the pressurized system that is being used.

If the engine is operating above the normal rangeand steam becomes apparent, perform the followingprocedure:

1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut downimmediately or if the engine can be cooled byreducing the load.

Tachometer This gauge indicates enginespeed (rpm). When the throttle controllever is moved to the full throttle position

without load, the engine is running at high idle. Theengine is running at the full load rpm when thethrottle control lever is at the full throttle positionwith maximum rated load.

NOTICETo help prevent engine damage, never exceed thehigh idle rpm. Overspeeding can result in seriousdamage to the engine. The engine can be operatedat high idle without damage, but should never beallowed to exceed high idle rpm.

Ammeter This gauge indicates theamount of charge or discharge in thebattery charging circuit. Operation of the

indicator should be to the right side of 0(zero).

Fuel Level This gauge indicates the fuellevel in the fuel tank. The fuel level gaugeoperates when the START/STOP switch

is in the on position.

Service Hour Meter The gauge indicatesoperating time of the engine.

25Operation Section

Engine Starting

Engine Startingi01903008

Before Starting Engine

Before the engine is started, perform the requireddaily maintenance and any other periodicmaintenance that is due. Refer to the Operationand Maintenance Manual, Maintenance IntervalSchedule for more information.

For the maximum service life of the engine,make a thorough inspection within the enginecompartment before the engine is started. Lookfor the following items: oil leaks, coolant leaks,loose bolts, and excessive dirt and/or grease.Remove any excess dirt and/or grease buildup.Repair any faults that were identified during theinspection.

Inspect the cooling system hoses for cracks andfor loose clamps.

Inspect the alternator and accessory drive beltsfor cracks, breaks, and other damage.

Inspect the wiring for loose connections and forworn wires or frayed wires.

Check the fuel supply. Drain water from the waterseparator (if equipped). Open the fuel supplyvalve (if equipped).

NOTICEAll valves in the fuel return line must be open beforeand during engine operation to help prevent high fuelpressure. High fuel pressure may cause filter housingfailure or other damage.

If the engine has not been started for severalweeks, fuel may have drained from the fuel system.Air may have entered the filter housing. Also, whenfuel filters have been changed, some air pocketswill be trapped in the engine. In these instances,prime the fuel system. Refer to the Operation andMaintenance Manual, Fuel System - Prime formore information on priming the fuel system.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

Do not start the engine or move any of thecontrols if there is a DO NOT OPERATE warningtag or similar warning tag attached to the startswitch or to the controls.

Ensure that the areas around the rotating partsare clear.

All of the guards must be put in place. Check fordamaged guards or for missing guards. Repairany damaged guards. Replace damaged guardsand/or missing guards.

Disconnect any battery chargers that are notprotected against the high current drain thatis created when the electric starting motor isengaged. Check electrical cables and check thebattery for poor connections and for corrosion.

Reset all of the shutoffs or alarm components (ifequipped).

Check the engine lubrication oil level. Maintainthe oil level between the ADD mark and theFULL mark on the oil level dipstick.

Check the coolant level. Observe the coolantlevel in the header tank (if equipped). Maintainthe coolant level to the FULL mark on theheader tank.

If the engine is not equipped with a header tankmaintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel in the sight glass.

Observe the air cleaner service indicator (ifequipped). Service the air cleaner when theyellow diaphragm enters the red zone, or whenthe red piston locks in the visible position.

Ensure that any equipment that is driven by theengine has been disengaged from the engine.Minimize electrical loads or remove any electricalloads.

26Operation SectionEngine Starting

i01934161

Starting the Engine


NOTICEDo not crank the engine for more than 10 seconds.Allow the starter motor to cool for 30 seconds beforecranking again. Do not engage the starter when theflywheel is turning.

Refer to the OEM Manual for your type of controls.

1. Remove any load from the engine. Disengageany driven equipment.

2. Crank the engine. Start the engine.

3. If the engine does not start, release the enginestart switch and allow the electric starting motorto cool.

4. If the ambient temperature is low, activate theglow plugs according to Table 3.

Table 3

Preheat Times

Temperature Preheat Time5 C (41 F) 10 seconds

5 C (23 F) to 4 C (40 F) 20 secondsLess than 5 C (23 F) 30 seconds

Continuous Preheat 60 seconds maximum

5. Crank the engine. Start the engine.

6. Allow the engine to idle for 5 to 10 minutesbefore applying a load to the engine. Checkthe oil pressure gauge. The oil pressure gaugeshould be at the proper value.

i01929012

Starting with Jump StartCables

Improper jump start cable connections can causean explosion resulting in personal injury.Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jump startcable ends to contact each other or the engine.

Note: If it is possible, first diagnose the reasonfor the starting failure. Make any necessaryrepairs. If the engine will not start only due tothe condition of the battery, either charge thebattery, or start the engine with jump start cables.The condition of the battery can be recheckedafter the engine has been switched OFF.

NOTICEUsing a battery source with the same voltage as theelectric starting motor. Use ONLY equal voltage forjump starting. The use of higher voltage will damagethe electrical system.

Do not reverse the battery cables. The alternator canbe damaged. Attach ground cable last and removefirst.

When using an external electrical source to start theengine, turn the engine control switch to the OFF po-sition. Turn all electrical accessories OFF before at-taching the jump start cables.Ensure that the main power switch is in the OFF posi-tion before attaching the jump start cables to the en-gine being started.

1. Turn the start switch to the OFF position. Turn offall the engines accessories.

2. Connect one positive end of the jump start cableto the positive cable terminal of the dischargedbattery. Connect the other positive end of thejump start cable to the positive cable terminalof the electrical source.

27Operation Section

Engine Starting

3. Connect one negative end of the jump start cableto the negative cable terminal of the electricalsource. Connect the other negative end of thejump start cable to the engine block or to thechassis ground. This procedure helps to preventpotential sparks from igniting the combustiblegases that are produced by some batteries.

4. Start the engine.

5. Immediately after the stalled engine is started,disconnect the jump start cables in reverse order.

After jump starting, the alternator may not beable to fully recharge batteries that are severelydischarged. The batteries must be replaced orcharged to the proper voltage with a battery chargerafter the engine is stopped. Many batteries whichare considered unusable are still rechargeable.Refer to Operation and Maintenance Manual,Battery - Replace and Testing and AdjustingManual, Battery - Test.

i01903609

After Starting Engine

Note: In temperatures from 0 to 60C (32 to 140F),the warm-up time is approximately three minutes. Intemperatures below 0C (32F), additional warm-uptime may be required.

When the engine idles during warm-up, observethe following conditions:

Check for any fluid or for any air leaks at idle rpmand at one-half full rpm (no load on the engine)before operating the engine under load. This isnot possible in some applications.

Operate the engine at low idle until all systemsachieve operating temperatures. Check allgauges during the warm-up period.

Note: Gauge readings should be observed and thedata should be recorded frequently while the engineis operating. Comparing the data over time willhelp to determine normal readings for each gauge.Comparing data over time will also help detectabnormal operating developments. Significantchanges in the readings should be investigated.

28Operation SectionEngine Operation

Engine Operationi01903587

Engine Operation

Proper operation and maintenance are key factorsin obtaining the maximum life and economy ofthe engine. If the directions in the Operation andMaintenance Manual are followed, costs canbe minimized and engine service life can bemaximized.

The engine can be operated at the rated rpm afterthe engine reaches operating temperature. Theengine will reach normal operating temperaturesooner during a low engine speed (rpm) andduring a low power demand. This procedure ismore effective than idling the engine at no load.The engine should reach operating temperature ina few minutes.

Gauge readings should be observed and the datashould be recorded frequently while the engine isoperating. Comparing the data over time will helpto determine normal readings for each gauge.Comparing data over time will also help detectabnormal operating developments. Significantchanges in the readings should be investigated.

i01934633

Fuel Conservation Practices

The efficiency of the engine can affect the fueleconomy. Perkins design and technology inmanufacturing provides maximum fuel efficiencyin all applications. Follow the recommendedprocedures in order to attain optimum performancefor the life of the engine.

Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuelmay overflow from the fuel tank. Inspect fuel linesfor leaks. Repair the fuel lines, as needed.

Be aware of the properties of the different fuels.Use only the recommended fuels.

Avoid unnecessary idling.

Shut off the engine rather than idle for long periodsof time.

Observe the service indicator frequently. Keepthe air cleaner elements clean.

Maintain a good electrical system.

One damaged battery cell will overwork thealternator. This will consume excess power andexcess fuel.

Ensure that the belts are properly adjusted. Thebelts should be in good condition.

Ensure that all of the connections of the hosesare tight. The connections should not leak.

Ensure that the driven equipment is in goodworking order.

Cold engines consume excess fuel. Utilize heatfrom the jacket water system and the exhaustsystem, when possible. Keep cooling systemcomponents clean and keep cooling systemcomponents in good repair. Never operate theengine without water temperature regulators.All of these items will help maintain operatingtemperatures.

29Operation Section

Engine Stopping

Engine Stoppingi01935195

Stopping the Engine

NOTICEStopping the engine immediately after it has beenworking under load, can result in overheating and ac-celerated wear of the engine components.

Avoid accelerating the engine prior to shutting it down.

Avoiding hot engine shutdowns will maximize tur-bocharger shaft and bearing life.

Note: Individual applications will have differentcontrol systems. Ensure that the shutoff proceduresare understood. Use the following generalguidelines in order to stop the engine.

1. Remove the load from the engine. Reduce theengine speed (rpm) to low idle. Perform thisprocedure for five to six minutes in order to coolthe engine.

2. Stop the engine after the cool down periodaccording to the shutoff system on the engineand turn the ignition key switch to the OFFposition. If necessary, refer to the instructionsthat are provided by the OEM.

i01903586

Emergency Stopping

NOTICEEmergency shutoff controls are for EMERGENCY useONLY. DO NOT use emergency shutoff devices orcontrols for normal stopping procedure.

The OEM may have equipped the application withan emergency stop button. For more informationabout the emergency stop button, refer to the OEMinformation.

Ensure that any components for the external systemthat support the engine operation are secured afterthe engine is stopped.

i01935215

After Stopping Engine

Note: Before you check the engine oil, do notoperate the engine for at least 10 minutes in orderto allow the engine oil to return to the oil pan.

Check the crankcase oil level. Maintain the oillevel between the MIN mark and the MAXmark on the oil level dipstick.

If necessary, perform minor adjustments. Repairany leaks and tighten any loose bolts.

If the engine is equipped with a service hourmeter, note the reading. Perform the maintenancethat is in the Operation and Maintenance Manual,Maintenance Interval Schedule.

Fill the fuel tank in order to help preventaccumulation of moisture in the fuel. Do notoverfill the fuel tank.

NOTICEOnly use antifreeze/coolant mixtures recommended inthe Coolant Specifications that are in the Operationand Maintenance Manual. Failure to do so can causeengine damage.

Allow the engine to cool. Check the coolant level.

If freezing temperatures are expected, checkthe coolant for proper antifreeze protection. Thecooling system must be protected against freezingto the lowest expected outside temperature. Addthe correct coolant/water mixture, if necessary.

Perform all required periodic maintenance on alldriven equipment. This maintenance is outlined inthe instructions from the OEM.

30Operation SectionCold Weather Operation

Cold Weather Operationi01903584

Cold Weather Operation

Perkins Diesel Engines can operate effectively incold weather. During cold weather, the starting andthe operation of the diesel engine is dependent onthe following items:

The type of fuel that is used

The viscosity of the oil

The operation of the air inlet heater starting aid

Optional Cold starting aid

The purpose of this section will cover the followinginformation:

Explain potential problems that are caused bycold weather operation.

Suggest steps which can be taken in orderto minimize starting problems and operatingproblems when the ambient air temperature iscolder than 0 to 55 C (32 to 67 F).

The operation and maintenance of an engine infreezing temperatures is complex. This is becauseof the following conditions: the unlimited differencesin weather conditions, engine applications, andthe supplies that are available in your area. Thesefactors and recommendations from your Perkinsdealer are based on past proven practices. Theinformation that is contained in this section shouldbe combined in order to provide guidelines for coldweather operations.

Hints for Cold Weather Operation If the engine will start, operate the engine until a

minimum operating temperature of 71 C (160 F)is achieved. Achieving operating temperature willhelp prevent the intake valves and exhaust valvesfrom sticking.

The cooling system and the lubrication system forthe engine do not lose heat immediately uponshutdown. This means that an engine can be shutdown for a few hours and the engine can still havethe ability to start readily. If the engine is shutdown for at least eight hours, the engine shouldbe considered cooled to outside temperature.

Install the correct lubricant in each compartmentbefore the beginning of cold weather.

Check all rubber parts (hoses, fan drive belts,etc) weekly.

Check all electrical wiring and connections forany fraying or damaged insulation.

Keep all batteries fully charged and warm.

Fill the fuel tank at the end of each shift.

Check the air cleaners and the air intake daily.Check the air intake more often when you operatein snow.

Personal injury or property damage can resultfrom alcohol or starting fluids.

Alcohol or starting fluids are highly flammable andtoxic and if improperly stored could result in injuryor property damage.


For jump starting with cables in cold weather,refer to the Operation and Maintenance Manual,Starting with Jump Start Cables. for instructions.

Viscosity of the Engine LubricationOilProper engine oil viscosity is essential. Oil viscosityaffects the amount of torque that is needed tocrank the engine. Refer to the Operation andMaintenance Manual, Lubricant Specifications forthe recommended viscosity of oil.

Recommendations for the CoolantProvide cooling system protection for the lowestexpected outside temperature. Refer to theOperation and Maintenance Manual, GeneralCoolant Information for the recommended coolantmixture.

In cold weather, check the coolant often for theproper glycol concentration in order to ensureadequate freeze protection.

31Operation Section


Engine Block HeatersEngine block heaters (if equipped) heat theengine jacket water that surrounds the combustionchambers. This provides the following functions:

Startability is improved.

Warm up time is reduced.

An electric block heater can be activated oncethe engine is stopped. An effective block heateris typically a 1250/1500 W unit. Consult yourPerkins dealer or your Perkins distributor for moreinformation.

Idling the EngineWhen idling after the engine is started in coldweather, increase the engine rpm from 1000 to 1200rpm. This will warm up the engine more quickly.Maintaining an elevated low idle speed for extendedperiods will be easier with the installation of a handthrottle. The engine should not be raced in orderto speed up the warm up process.

While the engine is idling, the application of a lightload (parasitic load) will assist in maintaining theminimum operating temperature. The minimumoperating temperature is 71 C (160 F).

Recommendations for CoolantWarm UpWarm up an engine that has cooled below normaloperating temperatures due to inactivity. This shouldbe performed before the engine is returned to fulloperation. During operation in very cold temperatureconditions, damage to engine valve mechanismscan result from engine operation for short intervals.This can happen if the engine is started andthe engine is stopped many times without beingoperated in order to warm up completely.

When the engine is operated below normaloperating temperatures, fuel and oil are notcompletely burned in the combustion chamber.This fuel and oil causes soft carbon deposits toform on the valve stems. Generally, the deposits donot cause problems and the deposits are burnedoff during operation at normal engine operatingtemperatures.

When the engine is started and the engine isstopped many times without being operated inorder to warm up completely, the carbon depositsbecome thicker. This will cause the followingproblems:

Free operation of the valves is prevented.

Valves become stuck.

Pushrods are bent.

Other damage to valve train components canresult.

For this reason, when the engine is started,the engine must be operated until the coolanttemperature is 71 C (160 F) minimum. Carbondeposits on the valve stems will be kept at aminimum and the free operation of the valves andthe valve components will be maintained.

In addition, the engine must be thoroughly warmedin order to keep other engine parts in bettercondition and the service life of the engine will begenerally extended. Lubrication will be improved.There will be less acid and less sludge in the oil.This will provide longer service life for the enginebearings, the piston rings, and other parts. However,limit unnecessary idle time to ten minutes in orderto reduce wear and unnecessary fuel consumption.

Purge Valve and Insulated Heater LinesThe engine is equipped with a water temperatureregulator in order to allow the engine to reach thecorrect operating temperature quickly. The watertemperature regulator remains in the closed positionuntil the jacket water coolant temperature hasreached the engines operating temperature. Thejacket water circulates from the top of the cylinderblock, to the water temperature regulator housing,and back to the bottom of the cylinder block viathe bypass. The water temperature regulator allowssome flow of water and/or air to pass through thewater temperature regulator in order to ensure acontinuous flow of coolant within the cylinder block.This is achieved via a small jiggle valve in thewater temperature regulator. The water temperatureregulator moves to the open position when thejacket water coolant temperature has reachedthe correct operating temperature. The watertemperature regulator moves to the open position inorder to allow the passage of the coolant throughthe radiator to dissipate excess heat.

The above procedure is good for normal engineoperating conditions in temperate climates. Duringperiods of operations in a cold climate with a lightengine load, the coolant must bypass the radiatorin order to help prevent excessive cooling of theengine. Coolant that passes through the radiatormust be minimized in order to maintain the engineoperating temperature in cold weather.

32Operation SectionCold Weather Operation

Excessive cooling of the engine can be preventedby a valve that allows unnecessary coolant flow tobe diverted from the water temperature regulatorand back to the bottom of the engine block withoutpassing through the radiator.

Note: Perkins discourages the use of all airflowrestriction devices such as radiator shutters.Restriction of the airflow can result in the following:high exhaust temperatures, power loss, excessivefan usage, and reduction in fuel economy.

Cab heater lines for very cold weather are alsobeneficial. These lines provide more available heatfrom the coolant to the cab. The feed from theengine and the return lines from the cab should beinsulated in order to reduce heat loss to the outsideair.

Insulating the Air Inlet and EngineCompartmentWhen temperatures below 18 C (0 F) will befrequently encountered, an air cleaner inlet thatis located in the engine compartment may bespecified. An air cleaner that is located in theengine compartment may also minimize the entry ofsnow into the air cleaner. Also, heat that is rejectedby the engine helps to warm the intake air.

Additional heat can be retained around the engineby insulating the engine compartment.

i01935225

Fuel and the Effect from ColdWeather

Note: Only use grades of fuel that are recommendedby Perkins. Refer to this Operation and MaintenanceManual, Fuel Recommendations.

The following fuels can be used for the Perkins 800Series engine.

Group 1

Group 2

Group 3

Special Fuels

Perkins prefer only Group 1 and Group 2 fuels foruse in 800 Series engines. Group 3 fuels includeLow Temperature Fuels and Aviation KeroseneFuels.

Note: Group 3 fuels reduce the life of the engine.The use of Group 3 fuels is not covered by thePerkins warranty.

Special fuels include Biofuel.

Group 1 fuels are the preferred Group of Fuels forgeneral use by Perkins. Group 1 fuels maximizeengine life and engine performance. Group 1fuels are usually less available than Group 2 fuels.Frequently, Group 1 fuels are not available in colderclimates during the winter.

Note: Group 2 fuels must have a maximum wearscar of 650 micrometers (HFRR to ISO 12156-1).

Group 2 fuels are considered acceptable for issuesof warranty. This group of fuels may reduce the lifeof the engine, the engines maximum power, andthe engines fuel efficiency.

When Group 2 diesel fuels are used the followingcomponents provide a means of minimizingproblems in cold weather:

Glow plugs, which are standard equipment onall 800 Series engines

Engine coolant heaters, which may be an OEMoption

Fuel heaters, which may be an OEM option

Fuel line insulation, which may be an OEM option

There are three major differences between Group1 fuels and Group 2 fuels. Group 1 fuels have thefollowing different characteristics to Group 2 fuels.

A lower cloud point

A lower pour point

A higher rating of kJ (BTU) per unit volume of fuel

The cloud point is the temperature when a cloudof wax crystals begins to form in the fuel. Thesecrystals can cause the fuel filters to plug. Thepour point is the temperature when diesel fuel willthicken. The diesel fuel becomes more resistant toflow through fuel pumps and through the fuel lines.

Be aware of these values when diesel fuel ispurchased. Consider the average ambient airtemperature for the engines application. Enginesthat are fueled in one climate may not operate well ifthe engines are moved to another climate. Problemscan result due to changes in temperature.

33Operation Section


Before troubleshooting for low power or for poorperformance in the winter, check the type of fuelthat is being used.

Low temperature fuels may be available for engineoperation at temperatures below 0 C (32 F). Thesefuels limit the formation of wax in the fuel at lowtemperatures. Wax in the fuel may prevent the flowof the fuel through the fuel filters.

For more information on cold weather operation,see Operation and Maintenance Manual, ColdWeather Operation and Fuel Related Componentsin Cold Weather.

i01903588

Fuel Related Components inCold Weather

Fuel TanksCondensation can form in partially filled fuel tanks.Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision fordraining water and sediment from the bottom of thetanks. Some fuel tanks use supply pipes that allowwater and sediment to settle below the end of thefuel supply pipe.

Some fuel tanks use supply lines that take fueldirectly from the bottom of the tank. If the engine isequipped with this system, regular maintenance ofthe fuel system filter is important.

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

Fuel FiltersIt is possible that a primary fuel filter is installedbetween the fuel tank and the engine fuel inlet. Afteryou change the fuel filter, always prime the fuelsystem in order to remove air bubbles from the fuelsystem. Refer to the Operation and MaintenanceManual in the Maintenance Section for moreinformation on priming the fuel system.

The micron rating and the location of a primaryfuel filter is important in cold weather operation.The primary fuel filter and the fuel supply line arethe most common components that are affected bycold fuel.

Fuel HeatersNote: The OEM may equip the application with fuelheaters. If this is the case, disconnect an electrictype of fuel heater in warm weather in order toprevent overheating of the fuel. If the type of fuelheater is a heat exchanger, the OEM should haveincluded a bypass for warm weather. Ensure thatthe bypass is operational during warm weather inorder to prevent overheating of the fuel.

For more information about fuel heaters (ifequipped), refer to the OEM information.

34Maintenance SectionLubricant Specifications

Maintenance Section

Lubricant Specificationsi01903582

Lubricant Information

General InformationBecause of government regulations regardingthe certification of engine exhaust emissions, thelubricant recommendations must be followed.

Engine Manufacturers Association(EMA) OilsThe Engine Manufacturers AssociationRecommended Guideline on Diesel Engine Oil isrecognized by Perkins. For detailed informationabout this guideline, see the latest edition of EMApublication, EMA DHD -1.

API OilsThe Engine Oil Licensing and Certification Systemby the American Petroleum Institute (API) isrecognized by Perkins. For detailed informationabout this system, see the latest edition of the APIpublication No. 1509. Engine oils that bear the APIsymbol are authorized by API.

g00546535Illustration 16Typical API symbol

Diesel engine oils CC, CD, CD-2, and CE havenot been API authorized classifications since 1January 1996. Table 4 summarizes the status of theclassifications.

Table 4

API ClassificationsCurrent Obsolete

CF-4, CG-4, CH-4 CECF CC, CD

CF-2(1) CD-2(1)(1) The classifications CD-2 and American Petroleum Institute

CF-2 are for two-cycle diesel engines. Perkins does not sellengines that utilize CD-2 and API CF-2 oils.

TerminologyCertain abbreviations follow the nomenclature ofSAE J754. Some classifications follow SAE J183abbreviations, and some classifications followthe EMA Recommended Guideline on DieselEngine Oil. In addition to Perkins definitions, thereare other definitions that will be of assistance inpurchasing lubricants. Recommended oil viscositiescan be found in this publication, Engine Oil topic(Maintenance Section).

i01903583

Engine Oil

Commercial OilsThe performance of commercial diesel engineoils is based on American Petroleum Institute(API) classifications. These API classifications aredeveloped in order to provide commercial lubricantsfor a broad range of diesel engines that operate atvarious conditions.

Only use commercial oils that meet the followingclassifications:

EMA DHD-1 multigrade oil (preferred oil)

API CH-4 multigrade oil (preferred oil)

ACEAE3

In order to make the proper choice of a commercialoil, refer to the following explanations:

35Maintenance Section

Lubricant Specifications

EMA DHD-1 The Engine ManufacturersAssociation (EMA) has developed lubricantrecommendations as an alternative to the API oilclassification system. DHD-1 is a RecommendedGuideline that defines a level of oil performancefor these types of diesel engines: high speed, fourstroke cycle, heavy-duty, and light duty. DHD-1 oilsmay be used in Perkins engines when the followingoils are recommended: API CH-4, API CG-4, andAPI CF-4. DHD-1 oils are intended to providesuperior performance in comparison to API CG-4and API CF-4.

DHD-1 oils will meet the needs of high performancePerkins diesel engines that are operating in manyapplications. The tests and the test limits thatare used to define DHD-1 are similar to the newAPI CH-4 classification. Therefore, these oils willalso meet the requirements of the low emissionsdiesel engines. DHD-1 oils are designed to controlthe harmful effects of soot with improved wearresistance and improved resistance to plugging ofthe oil filter. These oils will also provide superiorpiston deposit control for engines with eithertwo-piece steel pistons or aluminum pistons.

All DHD-1 oils must complete a full test programwith the base stock and with the viscosity grade ofthe finished commercial oil. The use of API BaseOil Interchange Guidelines are not appropriate forDHD-1 oils. This feature reduces the variation inperformance that can occur when base stocks arechanged in commercial oil formulations.

DHD-1 oils are recommended for use in extendedoil change interval programs that optimize oil life.These oil change interval programs are basedon oil analysis. DHD-1 oils are recommended forconditions that demand a premium oil. Your Perkinsdealer or your Perkins distributor has the specificguidelines for optimizing oil change intervals.

API CH-4 API CH-4 oils were developed inorder to meet the requirements of the new highperformance diesel engines. Also, the oil wasdesigned to meet the requirements of the lowemissions diesel engines. API CH-4 oils are alsoacceptable for use in older diesel engines andin diesel engines that use high sulfur diesel fuel.API CH-4 oils may be used in Perkins engines thatuse API CG-4 and API CF-4 oils. API CH-4 oils willgenerally exceed the performance of API CG-4 oilsin the following criteria: deposits on pistons, controlof oil consumption, wear of piston rings, valve trainwear, viscosity control, and corrosion.

Three new engine tests were developed for theAPI CH-4 oil. The first test specifically evaluatesdeposits on pistons for engines with the two-piecesteel piston. This test (piston deposit) also measuresthe control of oil consumption. A second test isconducted with moderate oil soot. The secondtest measures the following criteria: wear of pistonrings, wear of cylinder liners, and resistance tocorrosion. A third new test measures the followingcharacteristics with high levels of soot in the oil:wear of the valve train, resistance of the oil inplugging the oil filter, and control of sludge.

In addition to the new tests, API CH-4 oils havetougher limits for viscosity control in applicationsthat generate high soot. The oils also have improvedoxidation resistance. API CH-4 oils must pass anadditional test (piston deposit) for engines that usealuminum pistons (single piece). Oil performance isalso established for engines that operate in areaswith high sulfur diesel fuel.

All of these improvements allow the API CH-4 oil toachieve optimum oil change intervals. API CH-4 oilsare recommended for use in extended oil changeintervals. API CH-4 oils are recommended forconditions that demand a premium oil. Your Perkinsdealer or your Perkins distributor has specificguidelines for optimizing oil change intervals.

Some commercial oils that meet the APIclassifications may require reduced oil changeintervals. To determine the oil change interval,closely monitor the condition of the oil and performa wear metal analysis.

NOTICEFailure to follow these oil recommendations can causeshortened engine service life due to deposits and/orexcessive wear.

Total Base Number (TBN) and FuelSulfur Levels for Direct Injection(DI) Diesel EnginesThe Total Base Number (TBN) for an oil depends onthe fuel sulfur level. For direct injection engines thatuse distillate fuel, the minimum TBN of the new oilmust be 10 times the fuel sulfur level. The TBN isdefined by ASTM D2896. The minimum TBN ofthe oil is 5 regardless of fuel sulfur level. Illustration17 demonstrates the TBN.

36Maintenance SectionLubricant Specifications

g00799818Illustration 17(Y) TBN by ASTM D2896(X) Percentage of fuel sulfur by weight(1) TBN of new oil(2) Change the oil when the TBN deteriorates to 50 percent of

the original TBN.

Use the following guidelines for fuel sulfur levelsthat exceed 1.5 percent:

Choose an oil with the highest TBN that meetsone of these classifications: EMA DHD-1 and APICH-4.

Reduce the oil change interval. Base the oilchange interval on the oil analysis. Ensure thatthe oil analysis includes the condition of the oiland a wear metal analysis.

Excessive piston deposits can be produced by anoil with a high TBN. These deposits can lead to aloss of control of the oil consumption and to thepolishing of the cylinder bore.

NOTICEOperating Direct Injection (DI) diesel engines with fuelsulphur levels over 0.5 percent will require shortenedoil change intervals in order to help maintain adequatewear protection.

Table 5

Percentage of Sulfur in thefuel

Oil change interval

Lower than 0.5 Normal

0.5 to 1.0 0.75 of normal

Greater than 1.0 0.50 of normal

Lubricant Viscosity Recommendationsfor Direct Injection (DI) Diesel EnginesThe proper SAE viscosity grade of oil is determinedby the minimum ambient temperature duringcold engine start-up, and the maximum ambienttemperature during engine operation.

Refer to Table 6 (minimum temperature) in orderto determine the required oil viscosity for startinga cold engine.

Refer to Table 6 (maximum temperature) in order toselect the oil viscosity for engine operation at thehighest ambient temperature that is anticipated.

Generally, use the highest oil viscosity thatis available to meet the requirement for thetemperature at start-up.

Table 6

Engine Oil ViscosityAmbient TemperatureEMA LRG-1

API CH-4Viscosity Grade Minimum Maximum

SAE 0W20 40 C (40 F) 10 C (50 F)SAE 0W30 40 C (40 F) 30 C (86 F)SAE 0W40 40 C (40 F) 40 C (104 F)SAE 5W30 30 C (22 F) 30 C (86 F)SAE 5W40 30 C (22 F) 40 C (104 F)SAE 10W30 20 C (4 F) 40 C (104 F)SAE 15W40 10 C (14 F) 50 C (122 F)

i01903738

Synthetic Base Stock Oils

Synthetic base oils are acceptable for use inthese engines if these oils meet the performancerequirements that are specified for the engine.

Synthetic base oils generally perform better thanconventional oils in the following two areas:

Synthetic base oils have improved flow at lowtemperatures especially in arctic conditions.

Synthetic base oils have improved oxidationstability especially at high operating temperatures.

Some synthetic base oils have performancecharacteristics that enhance the service life of theoil. Perkins does not recommend the automaticextending of the oil change intervals for any typeof oil.


Lubricant Specifications

i01903742

Re-refined Base Stock Oils

Re-refined base stock oils are acceptable foruse in Perkins engines if these oils meet theperformance requirements that are specified byPerkins. Re-refined base stock oils can be usedexclusively in finished oil or in a combination withnew base stock oils. The US military specificationsand the specifications of other heavy equipmentmanufacturers also allow the use of re-refined basestock oils that meet the same criteria.

The process that is used to make re-refined basestock oil should adequately remove all wear metalsthat are in the used oil and all the additives thatare in the used oil. The process that is used tomake re-refined base stock oil generally involvesthe process of vacuum distillation and hydrotreatingthe used oil. Filtering is adequate for the productionof high quality, re-refined base stock oil.

i01903752

Cold Weather Lubricants

When an engine is started and an engine isoperated in ambient temperatures below 20 C(4 F), use multigrade oils that are capable offlowing in low temperatures.

These oils have lubricant viscosity grades of SAE0W or SAE 5W.

When an engine is started and operated in ambienttemperatures below 30 C (22 F), use a syntheticbase stock multigrade oil with a 0W viscosity gradeor with a 5W viscosity grade. Use an oil with a pourpoint that is lower than 50 C (58 F).

The number of acceptable lubricants is limitedin cold weather conditions. Perkins recommendsthe following lubricants for use in cold weatherconditions:

First Choice Use oil with an EMA DHD-1Recommended Guideline. Use a CH-4 oil that hasan API license. The oil should be either SAE 0W20,SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40lubricant viscosity grade.

Second Choice Use an oil that has a CH-4additive package. Although the oil has not beentested for the requirements of the API license, the oilmust be either SAE 0W20, SAE 0W30, SAE 0W40,SAE 5W30, or SAE 5W40.

NOTICEShortened engine service life could result if secondchoice oils are used.

i01904027

Aftermarket Oil Additives

Perkins does not recommend the use of aftermarketadditives in oil. It is not necessary to use aftermarketadditives in order to achieve the engines maximumservice life or rated performance. Fully formulated,finished oils consist of base oils and of commercialadditive packages. These additive packages areblended into the base oils at precise percentages inorder to help provide finished oils with performancecharacteristics that meet industry standards.

There are no industry standard tests that evaluatethe performance or the compatibility of aftermarketadditives in finished oil. Aftermarket additives maynot be compatible with the finished oils additivepackage, which could lower the performance of thefinished oil. The aftermarket additive could fail tomix with the finished oil. This could produce sludgein the crankcase. Perkins discourages the use ofaftermarket additives in finished oils.

To achieve the best performance from a Perkinsengine, conform to the following guidelines:

Select the proper oil, or a commercial oil thatmeets the EMA Recommended Guideline onDiesel Engine Oil or the recommended APIclassification.

See the appropriate Lubricant Viscosities tablein order to find the correct oil viscosity grade foryour engine.

At the specified interval, service the engine. Usenew oil and install a new oil filter.

Perform maintenance at the intervals that arespecified in the Operation and MaintenanceManual, Maintenance Interval Schedule.

38Maintenance SectionFuel Specifications

Fuel Specificationsi01904061

Fuel Recommendations

To get the correct power and performance fromthe engine, use a fuel of the correct quality. Therecommended fuel specification for the Perkins1106 engine is shown below:

Cetane number__________________________45 minimum

Viscosity___________2,0 to 4.5 cSt at 40 C (104 F)

Density________________________0.835 to 0.855 Kg/liter

Sulfur_______________________0.2% of mass, maximum

Distillation___________________85% at 350 C (662 F)

Lubricity______________________________460 micrometersmaximum wear scar on ISO 12156 - 1

Cetane number

This indicates the properties of ignition of the fuel.Fuel with a low cetane number can be the rootcause of problems during cold start. This will affectcombustion.

Viscosity

This is the resistance to flow of a fluid. If thisresistance is outside the limits, the engine and theengine starting performance in particular can beaffected.

Sulfur

High sulfur content of the fuel is not normally foundin Europe, North America or Australasia. This cancause engine wear. When only high sulfur fuels areavailable, it will be necessary that high alkalinelubricating oil is used in the engine or that thelubricating oil change interval is reduced.

Distillation

This is an indication of the mixture of differenthydrocarbons in the fuel. A high ratio of light weighthydrocarbons can affect the characteristics ofcombustion.

Lubricity

This is the capability of the fuel to prevent pumpwear.

Diesel engines have the ability to burn a widevariety of fuels. These fuels are divided into fourgeneral groups:

Group 1 (preferred fuels)

Group 2 (permissible fuels)

Group 3 (aviation kerosene fuels)

Other fuels

Group 1 (preferred fuels): SpecificationDERV to EN590

Note: Only use Arctic fuels when the temperature isbelow 0 C (32 F). Do not use Arctic fuels whenthe ambient temperature is above 0 C (32 F).To ensure that the time period between crankingthe engine and first fire is kept to a minimum, onlyuse fuel of the correct viscosity and at the correcttemperature.

Gas oil to BS2869 Class A2

ASTM D975 - 91 Class 2D This can only be usedif the fuel has the correct specification of lubricity.

JIS K2204 (1992) Grades 1,2,3 and Special Grade3 This can only be used if the fuel has the correctspecification of lubricity.

Note: If low sulfur or low sulfur aromatic fuels areused, then fuel additives can be used to increaselubricity.

Group 2 (permissible fuels): SpecificationThese fuel specifications are considered acceptablefor issues of warranty. However,these fuels mayreduce the life of the engine, the engines maximumpower and the engines fuel efficiency.

ASTM D975 - 91 Class 1D

JP7, Mil T38219

NATO F63

NOTICEThese fuels should have a wear scar value of 650micrometers maximum HFRR to ISO 12156 - 1 andcan only be used on VP30 24 volt specifications.

Group 3 (aviation kerosene fuels): Specification


Fuel Specifications

These fuels need additives to achieve lubricity of650 micrometers wear scar and the reliability ofthe fuel injection pump will be reduced. The fuelinjection pump is not covered by a warranty, evenwhen the additives are included.

JP5 MIL T5624 (Avcat FSII, NATO F44

JP8 T83133 (Avtur FSII, NATO F34

Jet A

Jet A1, NATO F35, XF63

Low temperature fuels

Special fuels for use in cold weather may beavailable for engine operation at temperaturesbelow 0 C (32 F). These fuels limit the formationof wax in the fuel oil at low temperatures. If waxforms in the fuel oil, this could stop the flow of fueloil through the filter.

Note: These fuels that lack lubricity may cause thefollowing problems:

Lo

№82 Руководство по ремонту. Двигатель perkins 800 series

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