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Operationand Maintenance Manual

1104DIndustrialEngine

NH (Engine) NJ(Engine)

ImportantSafetyInformation

Mostaccidentsthatinvolveproductoperation,maintenanceandrepairarecausedbyfailureto observebasicsafetyrulesorprecautions.Anaccidentcanoftenbeavoidedbyrecognizingpotentially hazardoussituationsbeforeanaccidentoccurs.Apersonmustbealerttopotentialhazards.This personshouldalsohavethenecessarytraining,skillsandtoolstoperformthesefunctionsproperly. Improperoperation,lubrication,maintenanceorrepairofthisproductcanbedangerousand couldresultininjuryordeath.

Donotoperateorperformanylubrication,maintenanceorrepaironthisproduct,untilyouhave readandunderstoodtheoperation,lubrication,maintenanceandrepairinformation.

Safetyprecautionsandwarningsareprovidedinthismanualandontheproduct.Ifthesehazard warningsarenotheeded,bodilyinjuryordeathcouldoccurtoyouortootherpersons.

Thehazardsareidentifiedbythe“SafetyAlertSymbol”andfollowedbya“SignalWord”suchas “DANGER”,“WARNING”or“CAUTION”.TheSafetyAlert“WARNING”labelisshownbelow.

Themeaningofthissafetyalertsymbolisasfollows:

Attention!BecomeAlert!YourSafetyisInvolved.

Themessagethatappearsunderthewarningexplainsthehazardandcanbeeitherwrittenor pictoriallypresented.

Operationsthatmaycauseproductdamageareidentifiedby“NOTICE”labelsontheproductandin thispublication.

Perkinscannotanticipateeverypossiblecircumstancethatmightinvolveapotentialhazard.The warningsinthispublicationandontheproductare,therefore,notallinclusive.Ifatool,procedure, workmethodoroperatingtechniquethatisnotspecificallyrecommendedbyPerkinsisused, youmustsatisfyyourselfthatitissafeforyouandforothers.Youshouldalsoensurethatthe productwillnotbedamagedorbemadeunsafebytheoperation,lubrication,maintenanceor repairproceduresthatyouchoose.

Theinformation,specifications,andillustrationsinthispublicationareonthebasisofinformationthat wasavailableatthetimethatthepublicationwaswritten.Thespecifications,torques,pressures, measurements,adjustments,illustrations,andotheritemscanchangeatanytime.Thesechangescan affecttheservicethatisgiventotheproduct.Obtainthecompleteandmostcurrentinformationbefore youstartanyjob.Perkinsdealers or Perkins distributors havethemostcurrentinformationavailable.

Whenreplacementpartsarerequiredforthis productPerkinsrecommendsusingPerkins replacementparts.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Foreword

LiteratureInformation

Thismanualcontainssafety,operationinstructions, lubricationandmaintenanceinformation.This manualshouldbestoredinorneartheenginearea inaliteratureholderorliteraturestoragearea.Read, studyandkeepitwiththeliteratureandengine information.

EnglishistheprimarylanguageforallPerkins publications.TheEnglishusedfacilitatestranslation andconsistency.

Somephotographsorillustrationsinthismanual showdetails orattachmentsthatmaybedifferent fromyourengine.Guardsandcoversmayhave beenremovedforillustrativepurposes.Continuing improvementandadvancementofproductdesign mayhavecausedchangestoyourenginewhichare notincludedinthismanual.Wheneveraquestion arisesregardingyourengine,orthismanual,please consultwithyourPerkinsdealeroryourPerkins distributorforthelatestavailableinformation.

Safety

Thissafetysectionlistsbasicsafetyprecautions. Inaddition,thissectionidentifieshazardous, warningsituations.Readandunderstandthebasic precautionslistedinthesafetysectionbefore operatingorperforminglubrication,maintenanceand repairon thisproduct.

Operation

Operatingtechniquesoutlinedinthismanualare basic.Theyassistwithdevelopingtheskillsand techniquesrequiredtooperatetheenginemore efficientlyandeconomically.Skillandtechniques develop astheoperatorgainsknowledgeofthe engineanditscapabilities.

Theoperationsectionisareferenceforoperators. Photographsandillustrationsguidetheoperator throughproceduresofinspecting,starting,operating andstoppingtheengine.Thissectionalsoincludesa discussionofelectronicdiagnosticinformation.

Maintenance

Themaintenancesectionisaguidetoenginecare. Theillustrated,step-by-stepinstructionsaregrouped byservicehoursand/orcalendartimemaintenance intervals.Itemsinthemaintenancescheduleare referencedtodetailedinstructionsthatfollow.

Recommendedserviceshouldbeperformedatthe appropriateintervalsasindicatedintheMaintenance IntervalSchedule.Theactualoperatingenvironment oftheenginealsogovernstheMaintenanceInterval Schedule.Therefore,underextremelysevere, dusty,wetorfreezingcoldoperatingconditions, morefrequentlubricationandmaintenancethanis specifiedintheMaintenanceIntervalSchedulemay benecessary.

Themaintenancescheduleitemsareorganizedfor apreventivemaintenancemanagementprogram.If thepreventivemaintenanceprogramisfollowed,a periodictune-upisnotrequired.Theimplementation ofapreventivemaintenancemanagementprogram shouldminimizeoperatingcoststhroughcost avoidancesresultingfromreductionsinunscheduled downtimeandfailures.

MaintenanceIntervals

Performmaintenanceonitemsatmultiplesof theoriginalrequirement.Werecommendthatthe maintenanceschedulesbereproducedanddisplayed neartheengineasaconvenientreminder.Wealso recommendthatamaintenancerecordbemaintained aspartof theengine’spermanentrecord.

YourauthorizedPerkinsdealeroryourPerkins distributorcanassistyouinadjustingyour maintenancescheduletomeettheneedsofyour operatingenvironment.

Overhaul

Majorengineoverhauldetailsarenotcoveredin theOperationandMaintenanceManualexcept fortheintervalandthemaintenanceitemsinthat interval.Majorrepairsshouldonlybecarriedoutby Perkinsauthorizedpersonnel.YourPerkinsdealer oryourPerkinsdistributoroffersavarietyofoptions regardingoverhaulprograms.Ifyouexperience amajorenginefailure,therearealsonumerous afterfailureoverhauloptionsavailable.Consultwith yourPerkinsdealeroryourPerkinsdistributorfor informationregardingtheseoptions.

CaliforniaProposition65Warning

Dieselengineexhaustandsomeofitsconstituents areknowntotheStateofCaliforniatocausecancer, birth defects,andotherreproductiveharm.Battery posts,terminalsandrelatedaccessoriescontainlead andleadcompounds. Washhandsafterhandling

SafetySection

SafetyMessages

Theremaybeseveralspecificwarningsignsonyour engine.Theexactlocationandadescriptionofthe warningsignsarereviewedinthissection.Please becomefamiliarwithallwarningsigns.

Ensurethatallofthewarningsignsarelegible.Clean thewarningsignsorreplacethewarningsignsif thewordscannotbereadoriftheillustrationsare notvisible.Useacloth,water,andsoaptoclean thewarning signs.Donotusesolvents,gasoline,or otherharshchemicals.Solvents,gasoline,orharsh chemicalscouldloosentheadhesivethatsecuresthe warningsigns.Thewarningsignsthatareloosened coulddropoffoftheengine.

Replaceanywarningsignthatisdamagedor missing.Ifawarningsignisattachedtoapartofthe enginethatisreplaced,installanewwarningsignon thereplacementpart.YourPerkinsdealeroryour distributorcanprovidenewwarningsigns.

(1)UniversalWarning

Donotoperateorworkonthisequipmentunless youhavereadandunderstandtheinstructions andwarningsintheOperationandMaintenance Manuals.Failuretofollowtheinstructionsor heedthe warningscouldresultinseriousinjury ordeath.

TheUniversalWarninglabel(1)islocatedonboth sidesofthevalvemechanismcoverbase.Referto illustration2.

Illustration4 (2)Hand(HighPressure) (3)Ether

(3)Ether

Donotuseaerosoltypesofstartingaidssuchas ether.Suchusecouldresultinanexplosionand personalinjury.

g01187798

i02328435

g01154809

Illustration5

Typicalexample

Theetherwarninglabel(3)islocatedonthecoverof theinletmanifold.Refertoillustration4.

Illustration6

Attacha“DoNotOperate”warningtagorasimilar warningtagtothestartswitchortothecontrols before youservicetheequipmentorbeforeyou repairtheequipment.

g00104545

Wearahardhat,protectiveglasses,andother protectiveequipment,asrequired.

Donotwearlooseclothingorjewelrythatcansnag oncontrolsoronotherpartsoftheengine.

Makesurethatallprotectiveguardsandallcovers aresecuredinplaceontheengine.

Keeptheenginefreefromforeignmaterial.Remove debris,oil,tools,andotheritemsfromthedeck,from walkways,andfromsteps.

Neverputmaintenancefluidsintoglasscontainers. Drainallliquidsintoasuitablecontainer.

Obeyalllocalregulationsforthedisposalofliquids.

Useallcleaningsolutionswithcare.

Reportallnecessaryrepairs.

Donotallowunauthorizedpersonnelonthe equipment.

Ensurethatthepowersupplyisdisconnectedbefore youworkonthebusbarortheglowplugs.

Performmaintenanceontheenginewiththe equipmentintheservicingposition.Refertothe OEMinformationfortheprocedureforplacingthe equipmentintheservicingposition.

PressureAirandWater

Pressurizedairand/orwatercancausedebris and/orhotwatertobeblownout.Thiscouldresultin personalinjury.

Thedirectapplicationofpressurizedairor pressurizedwatertothebodycouldresultinpersonal injury.

Whenpressurizedairand/orwaterisusedfor cleaning,wearprotectiveclothing,protectiveshoes, andeyeprotection.Eyeprotectionincludesgoggles oraprotectivefaceshield.

Themaximumairpressureforcleaningpurposes mustbebelow 205kPa(30psi).Themaximum waterpressureforcleaningpurposesmustbebelow 275kPa(40psi).

FluidPenetration

Pressurecanbetrappedinthehydrauliccircuitlong aftertheenginehasbeenstopped.Thepressurecan causehydraulicfluidoritemssuchaspipeplugsto escaperapidlyifthepressureisnotrelievedcorrectly.

Donotremove anyhydrauliccomponentsorparts untilpressurehasbeenrelievedorpersonalinjury mayoccur.Donotdisassembleanyhydraulic components orpartsuntilpressurehasbeenrelieved orpersonalinjurymayoccur.RefertotheOEM informationforanyproceduresthatarerequiredto relievethehydraulicpressure.

Alwaysuseaboardorcardboardwhenyoucheck foraleak.Leakingfluidthatisunderpressurecan penetratebodytissue.Fluidpenetrationcancause seriousinjuryandpossibledeath.Apinholeleakcan causesevereinjury.Iffluidisinjectedintoyourskin, youmustgettreatmentimmediately.Seektreatment fromadoctorthatisfamiliarwiththistypeofinjury.

ContainingFluidSpillage

Caremustbetakeninordertoensurethatfluids arecontainedduringperformanceofinspection, maintenance,testing,adjustingandrepairofthe engine.Makeprovisiontocollectthefluidwitha suitablecontainerbeforeanycompartmentisopened orbeforeanycomponentisdisassembled.

• Onlyusethetoolsthataresuitableforcollecting fluidsandequipmentthatissuitableforcollecting fluids.

Illustration7

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Illustration8

• Onlyusethetoolsthataresuitableforcontaining fluidsandequipmentthatissuitableforcontaining fluids.

Obeyalllocalregulationsforthedisposalofliquids.

i02334785

BurnPrevention

Donottouchanypartofanoperatingengine. Allowtheenginetocoolbeforeanymaintenanceis performedontheengine.

Oils

Hotoilandhotlubricatingcomponentscancause personalinjury.Donotallowhotoiltocontactthe skin.Also,donotallowhotcomponentstocontact theskin.

Batteries

Electrolyteisanacid.Electrolytecancausepersonal injury.Donotallowelectrolytetocontacttheskinor theeyes.Alwayswearprotectiveglassesforservicing batteries.Washhandsaftertouchingthebatteries andconnectors.Useofglovesisrecommended.

Contactwithhighpressurefuelmaycausefluid penetrationandburnhazards.Highpressurefuelspraymaycauseafirehazard.Failuretofollowtheseinspection,maintenanceandserviceinstructionsmaycausepersonalinjuryordeath.

Aftertheenginehasstopped,youmustwaitfor60 secondsinordertoallowthefuelpressuretobe purgedfromthehighpressurefuellinesbeforeany serviceorrepairisperformedontheenginefuellines.

Allowthepressuretobepurgedintheairsystem,in thehydraulicsystem,inthelubricationsystem,orin thecoolingsystembeforeanylines,fittingsorrelated itemsaredisconnected.

Coolant

Whentheengineisatoperatingtemperature,the enginecoolantishot.Thecoolantisalsounder pressure.Theradiatorandalllinestotheheatersor totheenginecontainhotcoolant.

Anycontactwithhotcoolantorwithsteamcancause severeburns.Allowcoolingsystemcomponentsto coolbeforethecoolingsystemisdrained.

Checkthecoolantlevelaftertheenginehasstopped andtheenginehasbeenallowedtocool.

Ensurethatthefillercapiscoolbeforeremovingthe fillercap.Thefillercapmustbecoolenoughtotouch withabarehand.Removethefillercapslowlyin ordertorelievepressure.

Coolingsystemconditionercontainsalkali.Alkalican causepersonalinjury.Donotallowalkalitocontact theskin,theeyes,orthemouth.

Allfuels,mostlubricants,andsomecoolantmixtures areflammable.

Flammablefluidsthatareleakingorspilledontohot surfaces orontoelectricalcomponentscancause afire.Firemaycausepersonalinjuryandproperty damage.

Aftertheemergencystopbuttonisoperatedensure thatyouallow15minutes,beforetheenginecovers areremoved.

Determinewhethertheenginewillbeoperatedinan environmentthatallowscombustiblegasestobe drawnintotheairinletsystem.Thesegasescould causetheenginetooverspeed.Personalinjury, propertydamage,orenginedamagecouldresult.

Iftheapplicationinvolvesthepresenceofcombustible gases, consultyourPerkinsdealerand/oryour Perkinsdistributorforadditionalinformationabout suitableprotectiondevices.

Illustration9

SafetySection

FirePreventionandExplosionPrevention

Removeallflammablecombustiblematerialsor conductivematerialssuchasfuel,oil,anddebrisfrom theengine.Donotallowanyflammablecombustible materialsorconductivematerialstoaccumulateon theengine.

Storefuelsandlubricantsincorrectlymarked containersawayfromunauthorizedpersons.Store oilyragsandanyflammablematerialsinprotective containers. Donotsmokeinareasthatareusedfor storingflammablematerials.

Donotexpose theenginetoanyflame.

Exhaustshields(ifequipped)protecthotexhaust componentsfromoilorfuelsprayincaseofaline, atube,orasealfailure.Exhaustshieldsmustbe installedcorrectly.

Donotweldonlinesortanksthatcontainflammable fluids.Donotflamecutlinesortanksthatcontain flammable fluid.Cleananysuchlinesortanks thoroughlywithanonflammablesolventpriorto weldingorflamecutting.

Wiringmustbekeptingoodcondition.Allelectrical wiresmustbecorrectlyroutedandsecurelyattached. Checkallelectricalwiresdaily.Repairanywires thatarelooseorfrayedbeforeyouoperatethe engine.Cleanallelectricalconnectionsandtighten allelectricalconnections.

Eliminateallwiringthatisunattachedorunnecessary. Donotuse anywiresorcablesthataresmallerthan therecommendedgauge.Donotbypassanyfuses and/orcircuitbreakers.

Arcingorsparkingcouldcauseafire.Secure connections,recommendedwiring,andcorrectly maintainedbatterycableswillhelptopreventarcing orsparking.

Aftertheenginehasstopped,youmustwaitfor60 secondsinordertoallowthefuelpressuretobe purgedfromthehighpressurefuellinesbeforeany serviceorrepairisperformedontheenginefuellines.

Ensurethattheengineisstopped.Inspectalllines andhosesforwearorfordeterioration.Thehoses mustbe correctlyrouted.Thelinesandhosesmust haveadequatesupportandsecureclamps.

Oilfiltersand fuelfiltersmustbecorrectlyinstalled. Thefilterhousingsmustbetightenedtothecorrect torque.RefertotheDisassemblyandAssembly manualformoreinformation.

Usecautionwhenyouarerefuelinganengine.Do notsmokewhileyouarerefuelinganengine.Donot refuelanenginenearopenflamesorsparks.Always stoptheenginebeforerefueling.

Gasesfromabatterycanexplode.Keepanyopen flamesorsparksawayfromthetopofabattery.Do notsmokeinbatterychargingareas.

Nevercheckthebatterychargebyplacingametal objectacrosstheterminalposts.Useavoltmeteror ahydrometer.

g00704059

Illustration10

g00704135

Illustration11

Incorrectjumpercableconnectionscancause anexplosionthatcanresultininjury.Referto theOperationSectionofthismanualforspecific instructions

Donotchargeafrozenbattery.Thismaycausean explosion.

Thebatteriesmustbekeptclean.Thecovers (ifequipped)mustbekeptonthecells.Usethe recommendedcables,connections,andbatterybox coverswhentheengineisoperated.

FireExtinguisher

Makesurethatafireextinguisherisavailable.Be familiarwiththeoperationofthefireextinguisher. Inspectthefireextinguisherandservicethefire extinguisherregularly.Obeytherecommendations ontheinstructionplate.

Lines,TubesandHoses

Donotbendhighpressurelines.Donotstrikehigh pressurelines.Donotinstallanylinesthatare damaged.

Leakscancausefires.ConsultyourPerkinsdealer oryourPerkinsdistributorforreplacementparts.

Replacethepartsifanyofthefollowingconditions arepresent:

• Highpressurefuellineorlinesareremoved.

• Endfittingsaredamagedorleaking.

• Outercoveringsarechafedorcut.

• Wiresareexposed.

• Outercoveringsareballooning.

• Flexiblepartofthehosesarekinked.

• Outercovershaveembeddedarmoring.

• Endfittingsaredisplaced.

Makesurethatallclamps,guards,andheatshields areinstalledcorrectly.Duringengineoperation,this willhelptopreventvibration,rubbingagainstother parts,andexcessiveheat.

CrushingPreventionand CuttingPrevention

Supportthecomponentcorrectlywhenworkbeneath thecomponentisperformed.

Unlessothermaintenanceinstructionsareprovided, neverattemptadjustmentswhiletheengineis running.

Stayclearofallrotatingpartsandofallmoving parts.Leave theguardsinplaceuntilmaintenance isperformed.Afterthemaintenanceisperformed, reinstalltheguards.

Keepobjectsawayfrommovingfanblades.Thefan bladeswillthrowobjectsorcutobjects.

Whenobjectsarestruck,wearprotectiveglassesin ordertoavoidinjurytotheeyes.

Chipsorotherdebrismayflyoffobjectswhenobjects arestruck.Beforeobjectsarestruck,ensurethatno onewillbeinjuredbyflyingdebris.

i02235492

MountingandDismounting

Inspectthesteps,thehandholds,andtheworkarea beforemountingtheengine.Keeptheseitemsclean andkeeptheseitemsingoodrepair.

Mounttheengineanddismounttheengineonlyat locationsthathavestepsand/orhandholds.Donot climbontheengine,anddonotjumpofftheengine.

Facetheengineinordertomounttheengineor dismounttheengine.Maintainathree-pointcontact withthestepsandhandholds.Usetwofeetandone handoruseonefootandtwohands.Donotuseany controlsashandholds.

Donotstandoncomponentswhichcannotsupport yourweight.Useanadequateladderoruseawork platform.Securetheclimbingequipmentsothatthe equipmentwillnotmove.

Donotcarrytoolsorsupplieswhenyoumountthe engineorwhenyoudismounttheengine.Useahand linetoraiseandlowertoolsorsupplies.

Donotsteponthehighpressurefuellines.Donot deflectthehighpressurefuellines.Donotbendor strikethehighpressurefuellines.Deformationor damageofthehighpressurefuellinesmaycausea pointofweaknessandpotentialfailure.

Donotcheckthehighpressurefuellineswiththe engineorthestartingmotorinoperation.Afterthe enginehasstoppedallow60secondstopassinorder toallowthepressuretobepurgedbeforeanyservice orrepairisperformedontheenginefuellines.

Donotloosen thehighpressurefuellinesinorder toremoveairfromthefuelsystem.Thisprocedure isnotrequired.

Visuallyinspectthehighpressurefuellinesbefore theengineisstarted.Thisinspectionshouldbeeach day.

Ifyouinspecttheengineinoperation,alwaysuse theproper inspectionprocedureinordertoavoid afluidpenetrationhazard.RefertoOperationand MaintenanceManual,“GeneralHazardInformation”.

• Inspectthehighpressurefuellinesfordamage, deformation,anick,acut,acrease,oradent.

• Donotoperatetheenginewithafuelleak.Ifthere isaleakdonottightentheconnectioninorder tostopthe leak.Theconnectionmustonlybe tightenedtotherecommendedtorque.Referto DisassemblyandAssemblyManual,“FuelInjection Lines-RemoveandFuelInjectionLines-Install”.

• Ifthehighpressurefuellinesaretorquedcorrectly andthehighpressurefuellinesareleakingthe highpressurefuellinesmustbereplaced.

• Ensurethatallclipsonthehighpressurefuellines areinplace.Donotoperatetheenginewithclips thataredamaged,missingorloose.

• Donotattachanyotheritemtothehighpressure fuellines.

• Loosenedhighpressurefuellinesmustbe replaced.Alsoremovedhighpressurefuellines mustbereplaced.RefertoDisassemblyand AssemblyManual,“FuelInjectionLines-Install”.

BeforeStartingEngine

Theinitialstart-upofanenginethatisnew,serviced orrepairedmakeprovisiontoshuttheengine off,inordertostopanoverspeed.Thismaybe accomplished byshuttingofftheairand/orfuel supplytotheengine.

Overspeedshutdownshouldoccurautomaticallyfor enginesthatarecontrolledelectronically.Ifautomatic shutdowndoesnotoccur,presstheemergencystop buttoninordertocutthefueland/orairtotheengine.

Inspecttheengineforpotentialhazards.

Beforestartingtheengine,ensurethatnooneison, underneath,orclosetotheengine.Ensurethatthe areaisfree ofpersonnel.

Ifequipped,ensurethatthelightingsystemforthe engineissuitablefortheconditions.Ensurethatall lightsworkcorrectly,ifequipped.

Allprotectiveguardsandallprotectivecoversmust beinstallediftheenginemustbestartedinorder toperformserviceprocedures.Tohelppreventan accidentthatiscausedbypartsinrotation,work aroundthepartscarefully.

Donotbypasstheautomaticshutoffcircuits.Donot disabletheautomaticshutoffcircuits.Thecircuitsare providedinordertohelppreventpersonalinjury.The circuits arealsoprovidedinordertohelpprevent enginedamage.

SeetheServiceManualforrepairsandfor adjustments.

EngineStarting

Donotuseaerosoltypesofstartingaidssuchas ether.Suchusecouldresultinanexplosionand personalinjury.

Ifawarningtagisattachedtotheenginestartswitch ortothecontrolsDONOTstarttheengineormove thecontrols.Consultwiththepersonthatattached thewarningtagbeforetheengineisstarted.

i02251260

SafetySection EngineStopping

Allprotective guardsandallprotectivecoversmust beinstallediftheenginemustbestartedinorder toperformserviceprocedures.Tohelppreventan accidentthat iscausedbypartsinrotation,work aroundthepartscarefully.

Starttheenginefromtheoperator’scompartmentor fromtheenginestartswitch.

Alwaysstart theengineaccordingtotheprocedure thatisdescribedintheOperationandMaintenance Manual,“EngineStarting”topicintheOperation Section.Knowingthecorrectprocedurewillhelpto preventmajordamagetotheenginecomponents. Knowingtheprocedurewillalsohelptoprevent personalinjury.

Toensurethatthejacketwaterheater(ifequipped) and/orthelubeoilheater(ifequipped)isworking correctly,checkthewatertemperaturegauge and/ortheoiltemperaturegaugeduringtheheater operation

Engineexhaustcontainsproductsofcombustion whichcanbeharmfultoyourhealth.Alwaysstartthe engineandoperatetheengineinawellventilated area.Iftheengineisstartedinanenclosedarea, venttheengineexhausttotheoutside.

Note: Theengineisequippedwithadeviceforcold starting.Iftheenginewillbeoperatedinverycold conditions,thenanextracoldstartingaidmaybe required.Normally,theenginewillbeequippedwith thecorrecttypeofstartingaidforyourregionof operation.

Theseenginesareequippedwithaglowplugstarting aidineachindividualcylinderthatheatstheintake airinordertoimprovestarting.

i02234873

EngineStopping

Stoptheengineaccordingtotheprocedurein theOperationandMaintenanceManual,“Engine Stopping(OperationSection)”inordertoavoid overheatingoftheengineandacceleratedwearof theenginecomponents.

UsetheEmergencyStopButton(ifequipped)ONLY inanemergencysituation.DonotusetheEmergency StopButtonfornormalenginestopping.Afteran emergencystop,DONOTstarttheengineuntilthe problemthatcausedtheemergencystophasbeen corrected.

Stoptheengine ifanoverspeedconditionoccurs duringtheinitialstart-upofanewengineoranengine thathasbeenoverhauled.

Tostopanelectronicallycontrolledengine,cutthe powertotheengineand/orshuttingofftheairsupply totheengine

i02234878

ElectricalSystem

Neverdisconnectanychargingunitcircuitorbattery circuitcablefromthebatterywhenthechargingunit isoperating.Asparkcancausethecombustible gasesthatareproducedbysomebatteriestoignite.

Tohelppreventsparksfromignitingcombustible gasesthatareproducedbysomebatteries,the negative“ ”cableshouldbeconnectedlastfromthe externalpowersourcetothenegative“ ”terminal ofthestartingmotor.Ifthestartingmotorisnot equippedwithanegative“ ”terminal,connectthe cabletotheengineblock.

Checktheelectricalwiresdailyforwiresthat arelooseorfrayed.Tightenalllooseelectrical connectionsbeforetheengineisstarted.Repairall frayedelectricalwiresbeforetheengineisstarted. SeetheOperationandMaintenanceManualfor specificstartinginstructions.

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GroundingPractices

Illustration13

Typicalexample (1)Startingmotortoengineblock (2)Groundtostartingmotor (3)Groundtobattery

g01162916

Uncontrolledelectricalcircuitpathscanresultin damagetothecrankshaftbearingjournalsurfaces andtoaluminumcomponents.

Enginesthatareinstalledwithoutengine-to-frame groundstrapscanbedamagedbyelectrical discharge.

Toensurethattheengineandtheengineelectrical systemsfunctioncorrectly,anengine-to-frame groundstrapwithadirectpathtothebatterymustbe used.Thispathmaybeprovidedbywayofadirect enginegroundtotheframe.

Theconnectionsforthegroundsshouldbetightand freeofcorrosion.Theenginealternatormustbe groundedtothenegative“-”batteryterminalwith awirethatisadequatetohandlethefullcharging currentofthealternator.

Thepowersupplyconnectionsandtheground connectionsfortheengineelectronicsshouldalways befromtheisolatortothebattery.

EngineElectronics

Tampering withtheelectronicsysteminstallation ortheOEMwiringinstallationcanbedangerous andcouldresultinpersonalinjuryordeathand/or enginedamage.

g01162918

Illustration14

Typicalexample (4)Groundtoengine (5)Groundtobattery

Correctgroundingfortheengineelectricalsystem isnecessaryforoptimumengineperformance andreliability.Incorrectgroundingwillresultin uncontrolledelectricalcircuitpathsandinunreliable electricalcircuitpaths.

ElectricalShockHazard.TheelectronicunitinjectorsuseDCvoltage.TheECMsendsthisvoltage totheelectronicunitinjectors.Donotcomein contactwiththeharnessconnectorfortheelectronicunitinjectorswhiletheengineisoperating. Failuretofollowthisinstructioncouldresultin personalinjuryordeath.

Thisenginehasacomprehensive,programmable EngineMonitoringSystem.TheElectronicControl Module(ECM)hastheabilitytomonitortheengine operatingconditions.Ifanyoftheengineparameters extendoutsideanallowablerange,theECMwill initiateanimmediateaction.

Thefollowingactionsareavailableforengine monitoringcontrol:

• Warning

• Derate

• Shutdown

Thefollowingmonitoredengineoperatingconditions havetheabilitytolimitenginespeedand/orthe enginepower:

• EngineCoolantTemperature

• EngineOilPressure

• EngineSpeed

• IntakeManifoldAirTemperature

TheEngineMonitoringpackagecanvaryfordifferent enginemodelsanddifferentengineapplications. However,themonitoringsystemandtheengine monitoringcontrolwillbesimilarforallengines.

Note: Manyof theenginecontrolsystemsanddisplay modulesthatareavailableforPerkinsEngineswill workinunisonwiththeEngineMonitoringSystem. Together,thetwocontrolswillprovidetheengine monitoringfunctionforthespecificengineapplication. RefertotheElectronicTroubleshootingManualfor moreinformationontheEngineMonitoringSystem.

ModelViews

ModelViewIllustrations

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Thefollowingmodelviewsshowtypicalfeatures oftheengine. Duetoindividualapplications,your enginemayappeardifferentfromtheillustrations.

Illustration16

Frontleftengineview (1)Frontliftingeye (2)Wateroutlet (3)Rearliftingeye (4)Fuelmanifold(rail) (5)Electroniccontrolmodule

(6)Oilgauge (7)Secondaryfuelfilter (8)Oilfiller (9)Oilsamplingvalve (10)Oilfilter

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(11)Crankshaftpulley (12)Waterpump (13)Belttensioner

Illustration17

Rearrightengineview (14)Turbocharger (15)Alternator (16)Exhaustmanifold (17)Wastegatesolenoid

(18)Startingmotor (19)Oilpan (20)Drainplug (21)Primaryfuelfilter

Note: Theprimaryfuelfiltermaybemountedoffthe engine.

i02378642

EngineDescription

The1104ElectronicEnginemodelsNHandNJare designedforthefollowingapplications:machineand industrialmobileequipment.Theengineisavailable inthefollowingtypeofaspiration:

• Turbocharged

• Turbochargedaftercooled

g01245940

(22)Handfuelprimingpump (23)Flywheelhousing (24)Heatshield

EngineSpecifications

Note: Thefrontendoftheengineisoppositethe flywheelendoftheengine.Theleftandtheright sidesoftheenginearedeterminedfromtheflywheel end.Thenumber1cylinderisthefrontcylinder.

Illustration18

(A)Exhaustvalves (B)Inletvalves

Table1

1104ElectronicEngineSpecifications

OperatingRange(rpm) 750to2650(1)

NumberofCylinders 4In-Line

Bore 105mm(4.13inch)

Stroke 127mm(5.0inch)

Aspiration NHTurbochargedengine NJTurbochargedengine thatisaftercooled

CompressionRatio 16.2:1

Displacement 4.4L(269in3)

FiringOrder 1,3,4,2

Rotation(flywheelend) Counterclockwise

ValveLashSetting(Inlet) 0.35mm(0.013inch)

ValveLashSetting (Exhaust) 0.35mm(0.013inch)

(1) Theoperatingrpmisdependentontheenginerating,the applicationandtheconfigurationofthethrottle.

ElectronicEngineFeatures

Theengineoperatingconditionsaremonitored. TheElectronicControlModule(ECM)controlsthe responseoftheenginetotheseconditionsandto thedemandsoftheoperator.Theseconditionsand operatordemandsdeterminetheprecisecontrolof fuelinjectionbytheECM.Theelectronicengine controlsystemprovidesthefollowingfeatures:

• Enginemonitoring

• Enginespeedgoverning

• Coldstartstrategy

• Automaticair/fuelratiocontrol

• Torqueriseshaping

• Injectiontimingcontrol

• Systemdiagnostics

Formoreinformationonelectronicenginefeatures, refertotheOperationandMaintenanceManual, “FeaturesandControls”topic(OperationSection).

EngineDiagnostics

Theenginehasbuilt-indiagnosticsinordertoensure thattheenginesystemsarefunctioningcorrectly.The operatorwillbealertedtotheconditionbya“Stopor Warning”lamp.Undercertainconditions,theengine horsepowerandthevehiclespeedmaybelimited. Theelectronicservicetoolmaybeusedtodisplay thediagnosticcodes.

Therearethreetypesofdiagnosticcodes:active, logged,andevent.

Mostofthediagnosticcodesareloggedandstored intheECM.Foradditionalinformation,referto theOperationandMaintenanceManual,“Engine Diagnostics”topic(OperationSection).

TheECMprovidesanelectronicgovernorthat controlstheinjectoroutputinordertomaintainthe desiredenginerpm.

EngineCoolingandLubrication

Thecoolingsystemconsistsofthefollowing components:

• Gear-drivencentrifugalwaterpump

• Watertemperatureregulatorwhichregulatesthe enginecoolanttemperature

• Gear-drivenoilpump(geartype)

• Oilcooler

Theengine lubricatingoilissuppliedbyagear typepump.Theenginelubricatingoiliscooledand theenginelubricatingoilisfiltered.Bypassvalves provideunrestrictedflowoflubricationoiltothe enginepartswhenoilviscosityishigh.Bypassvalves canalsoprovideunrestrictedflowoflubricationoil totheenginepartsiftheoilcoolershouldbecome pluggedoriftheoilfilterelementshouldbecome plugged.

Engineefficiency,efficiencyofemissioncontrols,and engineperformancedependonadherencetoproper operationandmaintenancerecommendations. Engineperformanceandefficiencyalsodependon theuseofrecommendedfuels,lubricationoils,and coolants.RefertothisOperationandMaintenance Manual,“MaintenanceIntervalSchedule”formore informationonmaintenanceitems.

ProductIdentification Information

PlateLocationsandFilm

Locations

i02378644

PerkinsdealersorPerkinsdistributorsneedallof thesenumbersinordertodeterminethecomponents thatwereincludedwiththeengine.Thispermits accurateidentificationofreplacementpartnumbers.

Thenumbersforfuelsettinginformationforelectronic enginesarestoredwithinthepersonalitymodule. ThesenumberscanbereadbyusingtheElectronic ServiceTool.

SerialNumberPlate(1)

Theengineserialnumberplateislocatedontheleft sideofthecylinderblocktotherearoftheengine.

g01248563

Illustration20

Serialnumberplate

ReferenceNumbers

g01094203

i02164876

Illustration19

Locationoftheserialnumberplate

Perkinsenginesareidentifiedbyanengineserial number.

Anexampleofanenginenumberis

NH*****U000001J.

Thelistnumberfortheengine

Informationforthefollowingitemsmaybeneededto orderparts.Locatetheinformationforyourengine. Recordtheinformationintheappropriatespace. Makeacopyofthislistforarecord.Keepthe informationforfuturereference.

RecordforReference

EngineModel

EngineSerialnumber

EngineLowIdlerpm

EngineFullLoadrpm

PrimaryFuelFilter

WaterSeparatorElement

SecondaryFuelFilterElement

LubricationOilFilterElement

AuxiliaryOilFilterElement

TotalLubricationSystemCapacity

TotalCooling SystemCapacity

AirCleanerElement

FanDriveBelt

AlternatorBelt

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Personalinjurycanresultfromhotcoolant.Any contactwithhotcoolantorwithsteamcancause severeburns.Allowcoolingsystemcomponents tocoolbeforethecoolingsystemisdrained.

4. Drainandrefillthecoolingsystem.Refertothis OperationandMaintenanceManual,“Cooling Systemcoolant(CommercialHeavyDutyChangeorCoolingSystemcoolant(ELC)Change”forinformationondraining,flushingand refillingthecoolingsystem.

5. Operatetheengineuntiltheenginereaches normaloperatingtemperature.Stoptheengine. Aftertheenginehasstopped,youmustwaitfor60 secondsinordertoallowthefuelpressuretobe purgedfromthehighpressurefuellinesbeforeany serviceorrepairisperformedontheenginefuel lines.Ifnecessary,performminoradjustments. Repairanyleaksfromthelowpressurefuel systemandfromthecooling,lubricationorair systems.Replaceanyhighpressurefuellinethat hasleaked.RefertoDisassemblyandassembly Manual,“FuelInjectionLines-Install”.

6. Drainthelubricatingoilfromtheoilpan.

Renewthecanister(s)ofthelubricatingoilfilter.

FilltheoilpantotheFullMarkontheengineoil levelgaugewithnew,cleanlubricatingoil.Add 1762811 POWERPARTLay-Up2totheoilin ordertoprotecttheengineagainstcorrosion.If 1762811 POWERPARTLay-Up2isnotavailable, useapreservativeofthecorrectspecification insteadofthelubricatingoil.Ifapreservativeis used,thismustbedrainedcompletelyattheend ofthestorageperiodandtheoilpanmustbe refilledtothecorrectlevelwithnormallubricating oil.

7. Operatetheengineinordertocirculateengineoil.

8. Disconnectthebattery.Ensurethatthebatteryis inafullychargedcondition.Protecttheterminals againstcorrosion. 1734115 POWERPART Lay-Up3canbeusedontheterminals.Putthe batteryintosafestorage.

9. Ifequipped,replacethecrankcasebreather element.Sealtheendofthebreatherpipe.

10. Removethevalvemechanismcover.Spray 1762811 POWERPARTLay-Up2aroundthe rockershaftassembly.

11. Removetheglowplugs.Slowlyrotatethe crankshaft.Bycheckingthevalves,positionthe pistonatBDC.Spray 1762811 POWERPART Lay-Up2fortwosecondsintothecylinderbore. Thisproceduremustbecarriedoutoneach cylinder.

12. Installtheglowplugs.Installthevalvemechanism cover.

13. Removethepipesthatareinstalledbetween theairfilterassemblyandtheturbocharger. Spray 1762811 POWERPARTLay-Up2into theturbocharger.Thedurationofthesprayis printedon thecontainer.Sealtheturbocharger withwaterprooftape.

14. Removethe exhaustpipefromtheoutputsideof theturbocharger.Spray 1762811 POWERPART Lay-Up2intotheturbocharger.Thedurationof thesprayisprintedonthecontainer.Sealthe turbochargerwithwaterprooftape.

15. Sealtheventofthefueltankorthefuelfillercap withwaterprooftape.

16. Removethe alternatordrivebeltandputthedrive beltintostorage.

17. Inordertopreventcorrosiontotheoutsideof theengine,spraytheenginewith 1734115 POWERPARTLay-Up3.Donotspraythearea insidethealternator.

OperationSection

GaugesandIndicators

i02322200

Yourenginemaynothavethesamegaugesorallof thegaugesthataredescribed.Formoreinformation aboutthegaugepackage,seetheOEMinformation.

Gaugesprovideindicationsofengineperformance. Ensurethatthegaugesareingoodworkingorder. Determinethenormaloperatingrangebyobserving thegaugesoveraperiodoftime.

Noticeablechangesingaugereadingsindicate potentialgaugeorengineproblems.Problemsmay alsobeindicatedbygaugereadingsthatchange evenifthereadingsarewithinspecifications. Determineandcorrectthecauseofanysignificant changeinthereadings.ConsultyourPerkinsdealer oryourPerkinsdistributorforassistance.

SomeengineapplicationsareequippedwithIndicator Lamps.Indicatorlampscanbeusedasadiagnostic aid.Therearetwolamps.Onelamphasanorange lensandtheotherlamphasaredlens.

Theseindicatorlampscanbeusedintwoways:

• Theindicatorlampscanbeusedtoidentifythe currentoperationalstatusoftheengine.The indicatorlampscanalsoindicatethattheengine hasafault.Thissystemisautomaticallyoperated viatheignitionswitch.

• Theindicatorlampscanbeusedtoidentifyactive diagnosticcodes.Thissystemisactivatedby pressingtheFlashCodebutton.

RefertotheTroubleshootingGuide,“Indicator Lamps”forfurtherinformation.

NOTICE

Ifnooilpressureisindicated,STOPtheengine.If maximumcoolanttemperatureisexceeded,STOP theengine.Enginedamagecanresult.

EngineOilPressure– Theoilpressure shouldbegreatestafteracoldengineis started.Thetypicalengineoilpressurewith SAE10W40is350to450kPa(50to65psi)atrated rpm.

Aloweroilpressureisnormalatlowidle.Iftheload isstableandthegaugereadingchanges,perform thefollowingprocedure:

1. Removetheload

2. Stoptheengine.

3. Checkandmaintaintheoillevel.

JacketWaterCoolantTemperature–Typicaltemperaturerangeis83°to95°C (181.4°to171°F).Themaximumallowable temperatureatsealevelwiththepressurizedcooling systemat48kPa(7psi)is103°C(217.4°F).Higher temperaturesmayoccurundercertainconditions. Thewatertemperaturereadingmayvaryaccording toload.Thetemperaturereadingshouldnever exceed7°C(44.6°F)belowtheboilingpointforthe pressurized systemthatisbeingused.

Iftheengineisoperatingabovethenormalrange andsteambecomesapparent,performthefollowing procedure:

1. Reducetheloadandtheenginerpm.

2. Determineiftheenginemustbeshutdown immediatelyoriftheenginecanbecooledby reducingtheload.

3. Inspectthecoolingsystemforleaks.

Tachometer– Thisgaugeindicatesengine speed(rpm).Whenthethrottlecontrollever ismovedtothefullthrottlepositionwithout load,theengineisrunningathighidle.Theengineis runningatthefullloadrpmwhenthethrottlecontrol leverisat thefullthrottlepositionwithmaximum ratedload.

NOTICE

Tohelppreventenginedamage,neverexceedthe highidlerpm.Overspeedingcanresultinserious damagetotheengine.Operationatspeedsexceedinghighidlerpmshouldbekepttoaminimum.

Ammeter– Thisgaugeindicatesthe amountofchargeordischargeinthe batterychargingcircuit.Operationofthe indicatorshouldbetothe“+”sideof“0”(zero).

FuelLevel– Thisgaugeindicatesthefuel levelinthefueltank.Thefuellevelgauge operateswhenthe“START/STOP”switch isinthe“on”position.

ServiceHourMeter– Thegaugeindicates totaloperatinghoursoftheengine.

FeaturesandControls

MonitoringSystem

“Warning”

i02308958

IftheShutdownmodehasbeenselectedandthe warningindicatoractivates,engineshutdownmay takeaslittleas20secondsfromthetimethewarningindicatorisactivated.Dependingontheapplication,specialprecautionsshouldbetakento avoidpersonalinjury.Theenginecanberestarted followingshutdownforemergencymaneuvers,if necessary.

NOTICE

TheEngineMonitoringSystemisnotaguarantee againstcatastrophicfailures.Programmeddelays andderateschedulesaredesignedtominimizefalse alarmsandprovidetimefortheoperatortostopthe engine.

Thefollowingparametersaremonitored:

• Coolanttemperature

• Intakemanifoldairtemperature

• Intakemanifoldairpressure

• Oilpressure

• Enginespeed/timing

ProgrammableOptionsand SystemsOperation

IftheWarning/Derate/Shutdownmodehasbeen selectedandthewarningindicatoractivates, bringtheenginetoastopwheneverpossible.Dependingontheapplication,specialprecautions shouldbetakentoavoidpersonalinjury.

Theenginecanbeprogrammedtothefollowing modes:

The“Warning”lampandthewarningsignal(orange lamp)turn“ON”andthewarningsignalisactivated continuouslyinordertoalerttheoperatorthatoneor moreoftheengineparametersisnotwithinnormal operatingrange.

“Warning/Derate”

The“Diagnostic”lampturns“ON”andthewarning signal(redlamp)isactivated.Afterthewarning,the enginepower willbederated.Thewarninglampwill begintoflashwhenthederatingoccurs.

Theenginewillbederatediftheengineexceeds presetoperationallimits.Theenginederateis achievedbyrestrictingtheamountoffuelthatis availableforeachinjection.Theamountofthis reductionoffuelisdependentontheseverityofthe faultthathascausedtheenginederate,typicallyup toalimitof50%.Thisreductioninfuelresultsina predeterminedreductioninenginepower.

“Warning/Derate/Shutdown”

The“Diagnostic”lampturns“ON”andthewarning signal(redlamp)isactivated.Afterthewarning, theenginepowerwillbederated.Theenginewill continueattherpmofthesetderateuntilashutdown oftheengineoccurs.Theenginecanberestarted afterashutdownforuseinanemergency.

Ashutdownoftheenginemayoccurinaslittle as20seconds.Theenginecanberestartedafter ashutdownforuseinanemergency.However, thecause oftheinitialshutdownmaystillexist. Theenginemayshutdownagaininaslittleas20 seconds.

Ifthereisasignalforlowoilpressureorforcoolant temperature,therewillbeatwoseconddelayin orderto verifythecondition.

Foreachoftheprogrammedmodes,referto TroubleshootingGuide,“IndicatorLamps”formore informationonIndicatorLamps.

Formore informationorassistanceforrepairs,consult yourPerkinsdealeroryourPerkinsdistributor.

i02296746

MonitoringSystem

Table2

Warning Lamp Shutdown Lamp LampStatus

Lampcheck

ON ON

OFF OFF Nofaults

ON OFF Active diagnostic fault

ON FLASHING Active diagnostic fault

FLASHING OFF

FLASHING FLASHING

ON ON

Warning

Derateand warning

Engine shutdown

SensorsandElectrical Components

SensorLocations

Descriptionoflampstatus

Whentheenginestartswitchisturnedtothe “ON”positionbothlampswillilluminatefor2 secondsonly.

Therearenoactivediagnosticfaults.

Anactivediagnosticfaulthasbeendetected.

Aseriousactivediagnosticfaulthasbeen detectedandanenginederatehasbeen invoked.

Oneormoreoftheengineprotectionvalues hasbeenexceeded.

Oneormoreoftheengineprotectionvalueshas beenexceededoraseriousactivediagnostic faulthasbeendetected.

i02378740

Illustration23showsthetypicallocationsofthe sensorsontheengine.Specificenginesmayappear differentfromtheillustrationduetodifferencesin applications.

EngineStatus

Theenginehasnotbeen started.

Theengineisrunning normally.

Theengineisrunning buttheenginehasbeen derated.

Theengineisrunning normally.

Theengineisrunning buttheenginehasbeen derated.

Theengineisshutdownor shutdownisimminent.

FailureofSensors

AllSensors

Afailureofanyofthesensorsmaybecausedbyone ofthefollowingmalfunctions:

• Sensoroutputisopen.

• Sensoroutputisshortedto“-battery”or“+battery”.

• Measuredreadingofthesensorisoutofthe specification.

ProgrammableMonitoringSystem (PMS)

TheProgrammableMonitoringSystemdetermines thelevelofactionthatistakenbytheEngineControl Module(ECM)inresponsetoaconditionthatcan damagetheengine.Theseconditionsareidentified bytheECMfromthesignalsthatareproducedfrom thefollowingsensors.

• CoolantTemperatureSensor

• BoostPressureSensor

• InletAirTemperatureSensor

• FuelPressureSensor

g01245095

Illustration24

• CrankshaftPositionSensors

• PositionSensor(Fuelinjectionpump)

• EngineOilPressureSensor

CoolantTemperatureSensor1

Thecoolanttemperaturesensormonitorsengine coolanttemperature.TheoutputoftheECMcan indicateahighcoolanttemperaturethrougharelay oralamp.Thecoolanttemperaturesensorisused bytheECMtodetermineinitiationoftheColdStart Condition.

FailureoftheCoolantTemperature Sensor

TheECMwilldetectafailureofthecoolant temperaturesensor.Thediagnosticlampwill warntheoperatoraboutthestatusofthecoolant temperaturesensor.Afailureofthecoolant temperaturesensorwillnotcauseashutdownof theengineoranyhorsepowerchange.Thefaulty sensorshouldbereplaced.RefertoDisassembly andAssemblyManual,“CoolantTemperatureSensor -RemoveandInstall”.

BoostPressureSensor2

Note: Thissensorhastwodifferentlocations.The locationdependsonthetypeofengine.

Theboostpressuresensormeasuresboostpressure intheinletairmanifold.AsignalissenttotheECM.

InletAir TemperatureSensor3

Theinletairtemperaturesensormeasurestheinlet airtemperature.AsignalissenttotheECM.The inletairtemperaturesensorisalsousedbytheECM todetermineinitiationoftheColdStartStrategy.

FuelPressureSensor4

Thefuelpressuresensormeasuresthefuelpressure inthefuelmanifold.AsignalissenttotheECM.

CrankshaftPositionSensor5

IftheECMdoesnotreceiveasignalfromthe crankshaftpositionsensor,the“DIAGNOSTIC”lamp willindicateadiagnosticfaultcodewhichwillbe loggedintheECMmemory.

IftheECMdoesnotreceiveasignalfromthe crankshaftpositionsensor(6),theECMwillread thesignalfromthepositionsensor(7).TheECM continuallychecksinordertodetermineifthereis asignalfrombothsensors.Ifeithersensorfails, thefaultysensorshouldbereplaced.Referto Disassembly andAssemblyManual,“Crankshaft PositionSensor-RemoveandInstall”.

Intermittentfailureofthesensorswillcauseerratic enginecontrol.

PositionSensorforthefuel injectionpump6

Thesignalfromthepositionsensor(7)isusedby theECMonenginestart-upinordertocheckthe strokeofthepistons.Thepositionsensormaybe usedbytheECMinordertooperatetheengineifthe crankshaftpositionsensorisfaulty.

EngineOil PressureSensor7

Note: Thissensorhastwodifferentlocations.The locationdependsonthetypeofengine.

Theengineoilpressuresensorisanabsolute pressuresensorthatmeasurestheengineoil pressureinthemainoilgallery.Theengineoil pressuresensordetectsengineoilpressurefor diagnosticpurposes.Theengineoilpressuresensor sendsasignaltotheECM.

LowOilPressureWarning

Thesetpointforthelowpressurewarningis dependentupontheenginespeed.Thefaultwillbe activeandloggedonlyiftheenginehasbeenrunning formorethan8seconds.

VeryLowOilPressureWarning

Theverylowoilpressuresetpointisdependentupon theenginespeed.IftheDERATEmodeoftheengine monitoringsystemisselected,theECMwillderate theenginepower.Theenginehorsepowerwillbe limited.

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EngineDiagnostics

Self-Diagnostics

i01902950

PerkinsElectronicEngineshavethecapabilityto performaself-diagnosticstest.Whenthesystem detectsanactiveproblem,adiagnosticlamp isactivated.Diagnosticcodeswillbestoredin permanentmemoryintheElectronicControlModule (ECM).Thediagnosticcodescanberetrieved byusingtheelectronicservicetool.Referto TroubleshootingGuide,“ElectronicServiceTools”for furtherinformation.

Someinstallationshaveelectronicdisplaysthat providedirectreadoutsoftheenginediagnostic codes.Refertothemanualthatisprovided bytheOEMformoreinformationonretrieving enginediagnosticcodes.Alternativelyrefertothe TroubleshootingGuide,“IndicatorLamps”forfurther information.

Activecodesrepresentproblemsthatcurrentlyexist. Theseproblemsshouldbeinvestigatedfirst.

Loggedcodesrepresentthefollowingitems:

• Intermittentproblems

• Recordedevents

• Performancehistory

Theproblemsmayhavebeenrepairedsincethe loggingofthecode.Thesecodesdonotindicatethat arepairisneeded.Thecodesareguidesorsignals whenasituationexists.Codesmaybehelpfulto troubleshootproblems.

Whentheproblemshavebeencorrected,the correspondingloggedfaultcodesshouldbecleared.

Usethefollowingproceduretoretrievetheflash codesiftheengineisequippedwitha“DIAGNOSTIC” lamp:

1. Turnthekeyswitch“ON/OFF”twotimeswithin3 seconds.

Aflashing“YELLOW”lampindicatesa3digitcodefor theengine.Thesequenceofflashesrepresentsthe systemdiagnosticmessage.Countthefirstsequence offlashesinordertodeterminethefirstdigitofthe flashcode.Afteratwosecondpause,thesecond sequenceofflasheswillidentifytheseconddigitof theflashcode.Afterthesecondpause,thethird sequenceofflasheswillidentifytheflashcode.

Anyadditionalflashcodeswillfollowafterapause. Thesecodeswillbedisplayedinthesamemanner. FlashCode551indicatesthatNoDetectedFaults haveoccurredsincetheignitionkeyswitchhasbeen turnedtotheONposition.

Forfurtherinformation,assistanceforrepairs,or troubleshooting,refertotheServiceManualor consultan authorizedPerkinsdealer.

Table3liststheflashcodesandthetablealsogives abriefdescriptionoftheflashcodes.

Note: Table3indicatesthepotentialeffectonengine performancewith“ACTIVE”flashcodes.

Somecodesrecordevents.Also,somecodes mayalsoindicatethatamechanicalsystemneeds attention.Troubleshootingisnotrequiredforcode “551”.Code001willnotdisplayaflashcode.Some codeswilllimittheoperationortheperformanceof theengine.

Table3indicatesthepotentialeffectontheengine performancewithactiveflashcodes.Table3also formsalistofElectronicdiagnosticcodesand descriptions.

Usethe“DIAGNOSTIC”Lamporanelectronic servicetooltodeterminethediagnosticflashcode.

(Table3,contd)

FlashCodesfortheIndustrialEngine

EffectOnEnginePerformance (1)

(1) An“X”indicatesthattheeffectonengineperformancemayoccurifthecodeisactive.

(2) ShutDowntheEngine:Operatetheenginecautiously.Getimmediateservice.Severeenginedamagemayresult.

(3) Theoperatorshouldgotothenearestlocationthathasaqualifiedserviceprogram.

(4) ScheduleService:Theproblemshouldbeinvestigatedwhentheoperatorhasaccesstoaqualifiedserviceprogram.

(5) TheseFlashCodesmayaffectthesystemunderspecificenvironmentalconditionssuchasenginestart-upatcoldtemperatureand coldweatheroperationathighaltitudes.

i01902948

DiagnosticLamp

Adiagnosticlampisusedtoindicatetheexistence ofanactivefault.RefertotheTroubleshooting Guide,“IndicatorLamps”formoreinformation.Afault diagnosticcodewillremainactiveuntiltheproblem isrepaired.Thediagnosticcodemayberetrieved byusingtheelectronicservicetool.Refertothe TroubleshootingGuide,“ElectronicServiceTools” formoreinformation.

i01902949

FaultLogging

ThesystemprovidesthecapabilityofFaultLogging. WhentheElectronicControlModule(ECM) generatesanactivediagnosticcode,thecodewill beloggedinthememoryoftheECM.Thecodes thathavebeenloggedbytheECMcanbeidentified bytheelectronicservicetool.Theactivecodesthat havebeenloggedwillbeclearedwhenthefault hasbeenrectifiedorthefaultisnolongeractive. Thefollowingloggedfaultscannotbeclearedfrom thememoryoftheECMwithoutusingafactory password:Overspeed,lowengineoilpressure,and highenginecoolanttemperature.

Ifadiagnosticlampilluminatesduringnormalengine operation,thesystemhasidentifiedasituationthatis notwithinthespecification.Usetheelectronicservice tooltochecktheactivediagnosticcodes.

Theactivediagnosticcodeshouldbeinvestigated. Thecauseoftheproblemshouldbecorrectedas soonaspossible.Ifthecauseoftheactivediagnostic codeisrepairedandthereisonlyoneactive diagnosticcode,thediagnosticlampwillturnoff.

Operationoftheengineandperformanceofthe enginecanbelimitedasaresultoftheactive diagnosticcodethatisgenerated.Accelerationrates maybesignificantlyslowerandpoweroutputsmaybe automaticallyreduced.RefertotheTroubleshooting Guide,“TroubleshootingwithaDiagnosticCode”for moreinformationontherelationshipbetweeneach activediagnosticcodeandthepossibleeffecton engineperformance.

i01902951

EngineOperationwith Intermittent DiagnosticCodes

Ifadiagnosticlampilluminatesduringnormalengine operationandthediagnosticlampshutsoff,an intermittent faultmayhaveoccurred.Ifafaulthas occurred,thefaultwillbeloggedintothememoryof theElectronicControlModule(ECM).

Inmostcases,itisnotnecessarytostoptheengine becauseofanintermittentcode.However,the operatorshouldretrievetheloggedfaultcodes andtheoperatorshouldreferencetheappropriate informationinordertoidentifythenatureoftheevent. Theoperatorshouldloganyobservationthatcould havecausedthelamptolight.

• Lowpower

• Limitsoftheenginespeed

• Excessivesmoke,etc

Thisinformationcanbeusefultohelptroubleshoot thesituation.Theinformationcanalsobeusedfor futurereference.Formoreinformationondiagnostic codes,refertotheTroubleshootingGuideforthis engine.

WhenGroup2dieselfuelisused,thefollowingitems provideameansofminimizingstartingproblems andfuelproblemsincoldweather:Engineoilpan heaters,jacketwaterheaters,fuelheaters,andfuel lineinsulation.

Usetheprocedurethatfollowsforcoldweather starting.

Note: Donotadjusttheenginespeedcontrolduring start-up.Theelectroniccontrolmodule(ECM)will controltheenginespeedduringstart-up.

1. Disengageanydrivenequipment.

2. TurnthekeyswitchtotheRUNposition.Leavethe keyswitchintheRUNpositionuntilthewarning lightfortheglowplugsisextinguished.

NOTICE

Donotengagethestartingmotorwhenflywheelis turning.Donotstarttheengineunderload.

Iftheenginefailstostartwithin30seconds,release thestarterswitchorbuttonandwaittwominutesto allowthestartingmotortocoolbeforeattemptingto starttheengineagain.

3. Whenthewarninglightfortheglowplugsis extinguishedturnthekeyswitchtotheSTART positioninordertoengagetheelectricstarting motorandcranktheengine.

Note: Theoperatingperiodofthewarninglightfor theglowplugswillchangeduetothetemperature oftheengine.

4. AllowthekeyswitchtoreturntotheRUNposition aftertheenginestarts.

5. Repeatstep2throughstep4iftheenginefails tostart.

Note: The engineshouldnotbe“raced”inorderto speedupthewarmupprocess.

6. Allowthe enginetoidleforthreetofiveminutes,or allowtheenginetoidleuntilthewatertemperature indicatorbeginstorise.Whenidlingafterthe enginehasstartedincoldweather,increasethe enginerpmfrom1000to1200rpm.Thiswill warmuptheenginemorequickly.Maintaining anelevatedlowidlespeedforextendedperiods willbeeasierwiththeinstallationofahand throttle.Allowthewhitesmoketodispersebefore proceedingwithnormaloperation.

7. Operatetheengineatlowloaduntilallsystems reachoperatingtemperature.Checkthegauges duringthewarm-upperiod.

StartingwithJumpStart Cables

Improperjumpstartcableconnectionscancause anexplosionresultinginpersonalinjury.

Preventsparksnearthebatteries.Sparkscould causevaporstoexplode.Donotallowjumpstart cableendstocontacteachotherortheengine.

Note: Ifitispossible,firstdiagnosethereasonfor thestartingfailure.RefertoTroubleshooting,“Engine WillNotCrankandEngineCranksButWillNotStart” forfurtherinformation.Makeanynecessaryrepairs.If theenginewillnotstartonlyduetotheconditionofthe battery,eitherchargethebattery,orstarttheengine byusinganotherbatterywithjumpstartcables. Theconditionofthebatterycanberechecked aftertheenginehasbeenswitchedOFF.

NOTICE

Usingabatterysourcewiththesamevoltageasthe electricstartingmotor.UseONLYequalvoltagefor jumpstarting.Theuseofhighervoltagewilldamage theelectricalsystem.

Donotreversethebatterycables.Thealternatorcan bedamaged.Attachgroundcablelastandremove first.

TurnallelectricalaccessoriesOFFbeforeattaching thejumpstartcables.

EnsurethatthemainpowerswitchisintheOFFpositionbeforeattachingthejumpstartcablestotheenginebeingstarted.

1. Turnthestartswitchonthestalledenginetothe OFFposition.Turnoffalltheengine’saccessories.

2. Connectonepositiveendofthejumpstartcable tothepositivecableterminalofthedischarged battery.Connecttheotherpositiveendofthejump startcabletothepositivecableterminalofthe electricalsource.

EngineOperation

i02330143

Correctoperationandmaintenancearekeyfactors inobtainingthemaximumlifeandeconomyof theengine.IfthedirectionsintheOperationand Maintenance Manualarefollowed,costscanbe minimizedandengineservicelifecanbemaximized.

Theenginecanbeoperatedattheratedrpmafterthe enginereachesoperatingtemperature.Theengine willreachnormaloperatingtemperatureiftheengine isoperated atlowidlespeedandoperatedwitha lightload.Thisprocedureismoreeffectivethanidling theengineatnoload.Theengineshouldreach operating temperatureinafewminutes.

Gaugereadingsshouldbeobservedandthedata shouldberecordedfrequentlywhiletheengine isoperating.Comparingthedataovertimewill helptodeterminenormalreadingsforeachgauge. Comparing dataovertimewillalsohelpdetect abnormaloperatingdevelopments.Significant changesinthereadingsshouldbeinvestigated.

i02330149

FuelConservationPractices

Theefficiency oftheenginecanaffectthefuel economy.Perkinsdesignandtechnologyin manufacturingprovidesmaximumfuelefficiencyin allapplications.Followtherecommendedprocedures inordertoattainoptimumperformanceforthelife oftheengine.

• Avoidspillingfuel.

Fuelexpands whenthefueliswarmedup.Thefuel mayoverflowfromthefueltank.Inspectfuellinesfor leaks.Repairthefuellines,asneeded.

• Beawareofthepropertiesofthedifferentfuels. Useonlytherecommendedfuels.

• Avoidunnecessaryidling.

Shutoffthe engineratherthanidleforlongperiodsof time.

• Observethe aircleanerserviceindicatorfrequently. Keeptheaircleanerelementsclean.

• Maintaintheelectricalsystems.

Onedamagedbatterycellwilloverworkthealternator. Thiswillconsumeexcesspowerandexcessfuel.

• Ensurethatthedrivebeltsarecorrectlyadjusted. Thedrivebeltsshouldbeingoodcondition.

• Ensurethatalloftheconnectionsofthehosesare tight.The connectionsshouldnotleak.

• Ensurethatthedrivenequipmentisingood workingorder.

• Coldenginesconsumeexcessfuel.Utilizeheat fromthejacketwatersystemandtheexhaust system,whenpossible.Keepcoolingsystem componentscleanandkeepcoolingsystem componentsingoodrepair.Neveroperatethe enginewithoutwatertemperatureregulators. Alloftheseitemswillhelpmaintainoperating temperatures.

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• Checkthecoolantforcorrectantifreezeprotection andthecorrectcorrosionprotection.Addthe correctcoolant/watermixture,ifnecessary.

• Performallrequiredperiodicmaintenanceonall drivenequipment.Thismaintenanceisoutlinedin theinstructionsfromtheOEM.

ColdWeatherOperation

PerkinsDieselEnginescanoperateeffectivelyin coldweather.Duringcoldweather,thestartingand theoperationofthedieselengineisdependenton thefollowingitems:

• Thetypeoffuelthatisused

• Theviscosityoftheengineoil

• Theoperationoftheglowplugs

• OptionalColdstartingaid

• Batterycondition

Thissectionwillcoverthefollowinginformation:

• Potentialproblemsthatarecausedbycoldweather operation

• Suggeststepswhichcanbetakeninorderto minimizestartingproblemsandoperatingproblems whentheambientairtemperatureisbetween 0°to 40°C(32°to40°F).

Theoperationandmaintenanceofanenginein freezingtemperaturesiscomplex.Thisisbecause ofthefollowingconditions:

• Weatherconditions

• Engineapplications

RecommendationsfromyourPerkinsdealeror yourPerkinsdistributorarebasedonpastproven practices.Theinformationthatiscontainedin thissectionprovidesguidelinesforcoldweather operation.

HintsforColdWeatherOperation

• Iftheenginewillstart,operatetheengineuntila minimumoperatingtemperatureof81°C(177.8°F) isachieved.Achievingoperatingtemperaturewill helppreventtheintakevalvesandexhaustvalves fromsticking.

• Thecoolingsystemandthelubricationsystem fortheenginedonotloseheatimmediatelyupon shutdown.Thismeansthatanenginecanbeshut downforaperiodoftimeandtheenginecanstill havetheabilitytostartreadily.

• Installthecorrectspecificationofenginelubricant beforethebeginningofcoldweather.

• Checkallrubberparts(hoses,fandrivebelts,etc) weekly.

• Checkallelectricalwiringandconnectionsforany frayingordamagedinsulation.

• Keepallbatteriesfullychargedandwarm.

• Fillthefueltankattheendofeachshift.

• Checktheaircleanersandtheairintakedaily. Checktheairintakemoreoftenwhenyouoperate insnow.

• Ensurethattheglowplugsareinworkingorder. RefertoTestingandAdjustingManual,“GlowPlug -Test”.

Personalinjuryorpropertydamagecanresult fromalcoholorstartingfluids.

Alcoholorstartingfluidsarehighlyflammableand toxicandifimproperlystoredcouldresultininjury orproperty damage.

Donotuseaerosoltypesofstartingaidssuchas ether.Suchusecouldresultinanexplosionand personalinjury.

• Forjumpstartingwithcablesincoldweather, refertotheOperationandMaintenanceManual, “StartingwithJumpStartCables.”forinstructions.

ViscosityoftheEngineLubrication Oil

Correctengineoilviscosityisessential.Oilviscosity affectstheamountoftorquethatisneededto cranktheengine.RefertothisOperationand MaintenanceManual,“FluidRecommendations”for therecommendedviscosityofoil.

RecommendationsfortheCoolant

Providecoolingsystemprotectionforthelowest expectedoutsidetemperature.RefertothisOperation andMaintenanceManual,“FluidRecommendations” fortherecommendedcoolantmixture.

Acabheaterisbeneficialinverycoldweather.The feedfromtheengineandthereturnlinesfromthe cabshouldbeinsulatedinordertoreduceheatloss totheoutside air.

InsulatingtheAirInletandEngine Compartment

Whentemperaturesbelow 18°C( 0°F)willbe frequentlyencountered,anaircleanerinletthat islocatedintheenginecompartmentmaybe specified.Anaircleanerthatislocatedintheengine compartment mayalsominimizetheentryofsnow intotheaircleaner.Also,heatthatisrejectedbythe enginehelpstowarmtheintakeair.

Additionalheatcanberetainedaroundtheengineby insulatingtheenginecompartment. i02322217

FuelandtheEffectfromCold Weather

Note: Onlyusegradesoffuelthatarerecommended byPerkins.RefertothisOperationandMaintenance Manual,“FluidRecommendations”.

Thefollowingfuelscanbeusedinthisseriesof engine.

• Group1

• Group2

• Group3

• SpecialFuels

PerkinspreferonlyGroup1andGroup2fuelsfor useinthisseriesofengines.

Group1fuelsarethepreferredGroupofFuelsfor generalusebyPerkins.Group1fuelsmaximize enginelifeandengineperformance.Group1fuels areusuallylessavailablethanGroup2fuels. Frequently,Group1fuelsarenotavailableincolder climatesduringthewinter.

Note: Group2fuelsmusthaveamaximumwear scarof650micrometers(HFRRtoISO12156-1).

Group2fuelsareconsideredacceptableforissues ofwarranty.Thisgroupoffuelsmayreducethelife oftheengine,theengine’smaximumpower,andthe engine’sfuelefficiency.

WhenGroup2dieselfuelsareusedthefollowing componentsprovideameansofminimizingproblems incoldweather:

• Glowplugs(ifequipped)

• Enginecoolantheaters,whichmaybeanOEM option

• Fuelheaters, whichmaybeanOEMoption

• Fuellineinsulation,whichmaybeanOEMoption

TherearethreemajordifferencesbetweenGroup 1fuelsandGroup2fuels.Group1fuelshavethe followingdifferentcharacteristicstoGroup2fuels.

• Alowercloudpoint

• Alowerpourpoint

• Ahigherenergyperunitvolumeoffuel

Note: Group3fuelsreducethelifeoftheengine.The useofGroup3 fuelsisnotcoveredbythePerkins warranty.

Group3fuels includeLowTemperatureFuelsand AviationKeroseneFuels.

SpecialfuelsincludeBiofuel.

Thecloudpointisatemperaturethatallowswax crystalsto forminthefuel.Thesecrystalscancause thefuelfilterstoplug.

Thepourpointisthetemperaturewhendieselfuel willthicken.Thedieselfuelbecomesmoreresistant toflowthroughfuellines,fuelfilters,andfuelpumps.

Beawareofthesefactswhendieselfuelis purchased.Considertheaverageambientair temperaturefortheengine’sapplication.Engines thatarefueledinoneclimatemaynotoperatewellif theenginesaremovedtoanotherclimate.Problems canresult duetochangesintemperature.

Beforetroubleshootingforlowpowerorforpoor performanceinthewinter,checkthefuelforwaxing.

Lowtemperaturefuelsmaybeavailableforengine operationattemperaturesbelow0°C(32°F).These fuelslimittheformationofwaxinthefuelatlow temperatures.

Formoreinformationoncoldweatheroperation,refer totheOperationandMaintenanceManual,“Cold WeatherOperationandFuelRelatedComponentsin ColdWeather”.

MaintenanceSection

RefillCapacities

LubricationSystem

i02378744

FluidRecommendations

GeneralLubricantInformation

i02543882

Becauseofgovernmentregulationsregardingthe certificationofexhaustemissionsfromtheengine, thelubricantrecommendationsmustbefollowed.

EngineManufacturersAssociation(EMA) Oils

Therefillcapacitiesfortheenginecrankcase reflecttheapproximatecapacityofthecrankcase orsumpplusstandardoilfilters.Auxiliaryoilfilter systemswillrequireadditionaloil.RefertotheOEM specificationsforthecapacityoftheauxiliaryoilfilter. RefertotheOperationandMaintenanceManual, “MaintenanceSection”formoreinformationon LubricantSpecifications.

Table4 Engine RefillCapacities

CompartmentorSystem

CrankcaseOilSump(1)

5L(1.1658 Impgal)

7L (1.5398 Impgal)

(1) Thesevaluesaretheapproximatecapacitiesforthecrankcase oilsump(aluminum)whichincludesthestandardfactory installedoilfilters.Engineswithauxiliaryoilfilterswillrequire additionaloil.RefertotheOEMspecificationsforthecapacity oftheauxiliaryoilfilter.

CoolingSystem

RefertotheOEMspecificationsfortheExternal Systemcapacity.Thiscapacityinformationwill beneededinordertodeterminetheamountof coolant/antifreezethatisrequiredfortheTotal CoolingSystem.

Table5 Engine RefillCapacities

CompartmentorSystem

EngineOnly

ExternalSystemPerOEM(1)

7L(1.5398 Impgal)

(1) TheExternalSystemincludesaradiatororanexpansion tankwiththefollowingcomponents:heatexchangerand piping.RefertotheOEMspecifications.Enterthevalueforthe capacityoftheExternalSysteminthisrow.

The“EngineManufacturersAssociation RecommendedGuidelineonDieselEngineOil”is recognizedbyPerkins.Fordetailedinformation aboutthisguideline,seethelatesteditionofEMA publication,“EMADHD-1”.

APIOils

TheEngineOilLicensingandCertificationSystemby theAmericanPetroleumInstitute(API)isrecognized byPerkins.Fordetailedinformationaboutthis system,see thelatesteditionofthe“APIpublication No.1509”.EngineoilsthatbeartheAPIsymbolare authorizedbyAPI.

g00546535

Illustration25 TypicalAPIsymbol

DieselengineoilsCC,CD,CD-2,andCEhave notbeenAPIauthorizedclassificationssince1 January1996.Table6summarizesthestatusofthe classifications.

MaintenanceSection

Table6

APIClassifications

Current Obsolete

CH-4,,CI-4 CE,CC,CD - CD-2 (1)

(1) TheoilCD-2isforatwo-cycledieselengine.Perkinsdoesnot sellenginesthatutilizeCD-2oil.

Terminology

Certainabbreviationsfollowthenomenclatureof “SAEJ754”.Someclassificationsfollow“SAEJ183” abbreviations,andsomeclassificationsfollowthe “EMARecommendedGuidelineonDieselEngine Oil”.InadditiontoPerkinsdefinitions,thereareother definitionsthatwillbeofassistanceinpurchasing lubricants.Recommendedoilviscositiescanbefound inthispublication,“FluidRecommendations/Engine Oil”topic(MaintenanceSection).

EngineOil

CommercialOils

Theperformanceofcommercialdieselengine oilsisbasedonAmericanPetroleumInstitute (API)classifications.TheseAPIclassificationsare developedinordertoprovidecommerciallubricants forabroadrangeofdieselenginesthatoperateat variousconditions.

Onlyusecommercialoilsthatmeetthefollowing classifications:

• APICH-4CI-4

Inordertomakethecorrectchoiceofacommercial oil,refertothefollowingexplanations:

EMADHD-1– TheEngineManufacturers Association(EMA)hasdevelopedlubricant recommendationsasanalternativetotheAPIoil classificationsystem.DHD-1isaRecommended Guidelinethatdefinesalevelofoilperformancefor thesetypesofdieselengines:highspeed,fourstroke cycle,heavy-duty,andlightduty.DHD-1oilsmay beusedinPerkinsengineswhenthefollowingoils arerecommended:APICH-4,APICG-4,andAPI CF-4.DHD-1oilsareintendedtoprovidesuperior performanceincomparisontoAPICG-4andAPI CF-4.

DHD-1oilswill meettheneedsofhighperformance Perkinsdieselenginesthatareoperatinginmany applications.Thetestsandthetestlimitsthatare usedtodefine DHD-1aresimilartothenewAPI CH-4classification.Therefore,theseoilswillalso meettherequirementsfordieselenginesthatrequire lowemissions.DHD-1oilsaredesignedtocontrolthe harmfuleffectsofsootwithimprovedwearresistance andimprovedresistancetopluggingoftheoilfilter. Theseoilswillalsoprovidesuperiorpistondeposit controlforengineswitheithertwo-piecesteelpistons oraluminumpistons.

AllDHD-1oilsmustcompleteafulltestprogram withthebasestockandwiththeviscositygradeof thefinishedcommercialoil.Theuseof“APIBase OilInterchangeGuidelines”arenotappropriatefor DHD-1oils.Thisfeaturereducesthevariationin performancethatcanoccurwhenbasestocksare changedincommercialoilformulations.

DHD-1oils arerecommendedforuseinextendedoil changeintervalprogramsthatoptimizethelifeofthe oil.Theseoilchangeintervalprogramsarebased onoilanalysis.DHD-1oilsarerecommendedfor conditionsthatdemandapremiumoil.YourPerkins dealeroryourPerkinsdistributorhasthespecific guidelinesforoptimizingoilchangeintervals.

APICH-4– APICH-4oilsweredevelopedinorderto meettherequirementsofthenewhighperformance dieselengines.Also,theoilwasdesignedto meettherequirementsofthelowemissionsdiesel engines.APICH-4oilsarealsoacceptableforuse inolderdieselenginesandindieselenginesthat usehighsulfurdieselfuel.APICH-4oilsmaybe usedin PerkinsenginesthatuseAPICG-4andAPI CF-4oils.APICH-4oilswillgenerallyexceedthe performanceofAPICG-4oilsinthefollowingcriteria: depositsonpistons,controlofoilconsumption,wear ofpistonrings,valvetrainwear,viscositycontrol, andcorrosion.

ThreenewenginetestsweredevelopedfortheAPI CH-4oil.Thefirsttestspecificallyevaluatesdeposits onpistonsforengineswiththetwo-piecesteelpiston. Thistest(pistondeposit)alsomeasuresthecontrol ofoilconsumption.Asecondtestisconducted withmoderateoilsoot.Thesecondtestmeasures thefollowingcriteria:wearofpistonrings,wearof cylinderliners,andresistancetocorrosion.Athird newtestmeasuresthefollowingcharacteristicswith highlevelsofsootintheoil:wearofthevalvetrain, resistanceoftheoilinpluggingtheoilfilter,and controlofsludge.

Inadditiontothenewtests,APICH-4oilshave tougherlimitsforviscositycontrolinapplicationsthat generatehighsoot.Theoilsalsohaveimproved oxidationresistance.APICH-4oilsmustpassan additionaltest(pistondeposit)forenginesthatuse aluminumpistons(singlepiece).Oilperformanceis alsoestablishedforenginesthatoperateinareas withhighsulfurdieselfuel.

AlloftheseimprovementsallowtheAPICH-4 oiltoachieveoptimumoilchangeintervals.API CH-4oilsarerecommendedforuseinextendedoil changeintervals.APICH-4oilsarerecommended forconditionsthatdemandapremiumoil.Your PerkinsdealeroryourPerkinsdistributorhasspecific guidelines foroptimizingoilchangeintervals.

SomecommercialoilsthatmeettheAPI classificationsmayrequirereducedoilchange intervals.Todeterminetheoilchangeinterval,closely monitortheconditionoftheoilandperformawear metalanalysis.

NOTICE

Failuretofollowtheseoilrecommendationscancause shortened engineservicelifeduetodepositsand/or excessivewear.

TotalBaseNumber(TBN)andFuelSulfur Levelsfor DirectInjection(DI)Diesel Engines

TheTotal BaseNumber(TBN)foranoildependson thefuelsulfurlevel.Fordirectinjectionenginesthat usedistillatefuel,theminimumTBNofthenewoil mustbe10 timesthefuelsulfurlevel.TheTBNis definedby“ASTMD2896”.TheminimumTBNofthe oilis5regardlessoffuelsulfurlevel.Illustration26 demonstratestheTBN.

Usethefollowingguidelinesforfuelsulfurlevelsthat exceed1.5percent:

• ChooseanoilwiththehighestTBNthatmeetsone oftheseclassifications:EMADHD-1andAPICH-4.

• Reducetheoil changeinterval.Basetheoil changeintervalontheoilanalysis.Ensurethatthe oilanalysisincludestheconditionoftheoiland awearmetalanalysis.

Excessivepistondepositscanbeproducedbyanoil withahighTBN.Thesedepositscanleadtoaloss ofcontroloftheoilconsumptionandtothepolishing ofthecylinderbore.

NOTICE

OperatingDirectInjection(DI)dieselengineswithfuel sulphurlevelsover0.5percentwillrequireshortened oilchangeintervalsinordertohelpmaintainadequate wearprotection.

Table7

PercentageofSulfurin thefuel Oilchangeinterval

Lowerthan0.5 Normal 0.5to1.0 0.75ofnormal

Greaterthan1.0 0.50ofnormal

LubricantViscosityRecommendations forDirectInjection(DI)DieselEngines

ThecorrectSAEviscositygradeofoilisdetermined bytheminimumambienttemperatureduring coldenginestart-up,andthemaximumambient temperatureduringengineoperation.

RefertoTable8(minimumtemperature)inorderto determinetherequiredoilviscosityforstartingacold engine.

RefertoTable8(maximumtemperature)inorderto selecttheoilviscosityforengineoperationatthe highestambienttemperaturethatisanticipated.

Generally,usethehighestoilviscositythatis availabletomeettherequirementforthetemperature atstart-up.

g00799818

Illustration26

(Y)TBNby“ASTMD2896”

(X)Percentageoffuelsulfurbyweight (1)TBNofnewoil

(2)ChangetheoilwhentheTBNdeterioratesto50percentof theoriginalTBN.

SAE0W20 40°C( 40°F) 10°C(50°F)

SAE0W30 40°C( 40°F) 30°C(86°F)

SAE0W40 40°C( 40°F) 40°C(104°F)

SAE5W30 30°C( 22°F) 30°C(86°F)

SAE5W40 30°C( 22°F) 40°C(104°F)

SAE10W30 20°C( 4°F) 40°C(104°F)

SAE15W40 10°C(14°F) 50°C(122°F)

SyntheticBaseStockOils

Syntheticbaseoilsareacceptableforusein theseenginesiftheseoilsmeettheperformance requirementsthatarespecifiedfortheengine.

Syntheticbaseoilsgenerallyperformbetterthan conventionaloilsinthefollowingtwoareas:

• Syntheticbaseoilshaveimprovedflowatlow temperaturesespeciallyinarcticconditions.

• Syntheticbaseoilshaveimprovedoxidation stabilityespeciallyathighoperatingtemperatures.

Somesyntheticbaseoilshaveperformance characteristicsthatenhancetheservicelifeofthe oil.Perkinsdoesnotrecommendtheautomatic extendingoftheoilchangeintervalsforanytypeof oil.

Re-refinedBaseStockOils

Re-refinedbasestockoilsareacceptablefor useinPerkinsenginesiftheseoilsmeetthe performancerequirementsthatarespecifiedby Perkins.Re-refinedbasestockoilscanbeused exclusivelyinfinishedoilorinacombinationwith newbasestockoils.TheUSmilitaryspecifications andthespecificationsofotherheavyequipment manufacturersalsoallowtheuseofre-refinedbase stockoilsthatmeetthesamecriteria.

Theprocessthatisusedtomakere-refinedbase stockoilshouldadequatelyremoveallwearmetals thatareintheusedoilandalltheadditivesthat areintheusedoil.Theprocessthatisusedto makere-refinedbasestockoilgenerallyinvolvesthe processofvacuumdistillationandhydrotreatingthe usedoil.Filteringisadequatefortheproductionof highquality,re-refinedbasestockoil.

Lubricantsfor ColdWeather

Whenanengineisstartedandanengineisoperated inambienttemperaturesbelow 20°C( 4°F),use multigradeoilsthatarecapableofflowinginlow temperatures.

TheseoilshavelubricantviscositygradesofSAE 0WorSAE5W.

Whenanengineisstartedandoperatedinambient temperaturesbelow 30°C( 22°F),useasynthetic basestockmultigradeoilwithan0Wviscositygrade orwitha5Wviscositygrade.Useanoilwithapour pointthatislowerthan 50°C( 58°F).

Thenumberofacceptablelubricantsislimitedin coldweatherconditions.Perkinsrecommendsthe followinglubricantsforuseincoldweatherconditions:

FirstChoice– UseoilwithanEMADHD-1 RecommendedGuideline.UseaCH-4oilthathas anAPIlicense.TheoilshouldbeeitherSAE0W20, SAE0W30,SAE0W40,SAE5W30,orSAE5W40 lubricant viscositygrade.

SecondChoice– UseanoilthathasaCH-4 additivepackage.Althoughtheoilhasnotbeen testedfortherequirementsoftheAPIlicense,theoil mustbeeitherSAE0W20,SAE0W30,SAE0W40, SAE5W30,orSAE5W40.

NOTICE

Shortenedengineservicelifecouldresultifsecond choiceoilsareused.

AftermarketOilAdditives

Perkinsdoesnotrecommendtheuseofaftermarket additivesinoil.Itisnotnecessarytouseaftermarket additivesinordertoachievetheengine’smaximum servicelifeorratedperformance.Fullyformulated, finishedoilsconsistofbaseoilsandofcommercial additivepackages.Theseadditivepackagesare blendedintothebaseoilsatprecisepercentagesin ordertohelpprovidefinishedoilswithperformance characteristicsthatmeetindustrystandards.

Therearenoindustrystandardteststhatevaluate theperformanceorthecompatibilityofaftermarket additivesinfinishedoil.Aftermarketadditivesmay notbecompatiblewiththefinishedoil’sadditive package,whichcouldlowertheperformanceofthe finishedoil.Theaftermarketadditivecouldfailto mixwiththefinishedoil.Thiscouldproducesludge inthecrankcase.Perkinsdiscouragestheuseof aftermarketadditivesinfinishedoils.

ToachievethebestperformancefromaPerkins engine,conformtothefollowingguidelines:

• Selectthecorrectoil,oracommercialoilthatmeets the“EMARecommendedGuidelineonDiesel EngineOil”ortherecommendedAPIclassification.

• Seetheappropriate“LubricantViscosities”tablein ordertofindthecorrectoilviscositygradeforyour engine.

• Atthespecifiedinterval,servicetheengine.Use newoilandinstallanewoilfilter.

• Performmaintenanceattheintervalsthatare specifiedin theOperationandMaintenance Manual,“MaintenanceIntervalSchedule”.

Oilanalysis

Someenginesmaybeequippedwithanoilsampling valve.Ifoil analysisisrequiredtheoilsamplingvalve isusedtoobtainsamplesoftheengineoil.Theoil analysiswillcomplementthepreventivemaintenance program.

Theoilanalysisisadiagnostictoolthatisusedto determineoilperformanceandcomponentwear rates.Contaminationcanbeidentifiedandmeasured throughtheuseoftheoilanalysis.Theoilanalysis includesthefollowingtests:

• TheWearRateAnalysismonitorsthewearofthe engine’smetals.Theamountofwearmetaland typeofwearmetalthatisintheoilisanalyzed.The increaseintherateofenginewearmetalinthe oilisasimportantasthequantityofenginewear metalintheoil.

• Testsare conductedinordertodetect contaminationoftheoilbywater,glycolorfuel.

• TheOilConditionAnalysisdeterminesthelossof theoil’slubricatingproperties.Aninfraredanalysis isusedtocomparethepropertiesofnewoiltothe propertiesoftheusedoilsample.Thisanalysis allowstechnicianstodeterminetheamountof deteriorationoftheoilduringuse.Thisanalysis alsoallowstechnicianstoverifytheperformance oftheoilaccordingtothespecificationduringthe entireoilchangeinterval.

FuelSpecifications

FuelRecommendations

Togetthecorrectpowerandperformancefrom theengine,useafuelofthecorrectquality.The recommendedfuelspecificationforPerkinsengines isshownbelow:

• Cetanenumber

45minimum

• Viscosity 2,0to4.5cStat40°C(104°F)

• Density 0.835to0.855Kg/liter

• Sulfur 0.2%ofmass,maximum

• Distillation 85%at350°C(662°F)

• Lubricity 460micrometers maximumwearscaron“ISO12156-1”

Cetanenumber

Thisindicatesthepropertiesofignitionofthefuel. Fuelwithalowcetanenumbercanbetheroot causeofproblemsduringcoldstart.Thiswillaffect combustion.

Viscosity

Thisistheresistancetoflowofafluid.Ifthis resistanceisoutsidethelimits,theengineandthe enginestartingperformanceinparticularcanbe affected.

Sulfur

Highsulfurcontentofthefuelisnotnormallyfound inEurope,NorthAmericaorAustralasia.Thiscan causeenginewear.Whenonlyhighsulfurfuels areavailable,itwillbenecessarythathighalkaline lubricatingoilisusedintheengineorthatthe lubricatingoilchangeintervalisreduced.

Distillation

Thisisanindicationofthemixtureofdifferent hydrocarbonsinthefuel.Ahighratiooflightweight hydrocarbonscanaffectthecharacteristicsof combustion.

Lubricity

Thisisthecapabilityofthefueltopreventpumpwear.

Dieselengineshavetheabilitytoburnawidevariety offuels.Thesefuelsaredividedintofourgeneral groups:

• Group1(preferredfuels)

• Group2(permissiblefuels)

• Group3(aviationkerosenefuels)

• Otherfuels

Group1(preferredfuels):Specification “DERVtoEN590”

Note: OnlyuseArcticfuelswhenthetemperatureis below0°C(32°F).DonotuseArcticfuelswhenthe ambienttemperatureisabove0°C(32°F).Toensure thatthetimeperiodbetweencrankingtheengineand firstfireiskepttoaminimum,onlyusefuelofthe correctviscosityandatthecorrecttemperature.

Gasoilto“BS2869ClassA2”

“ASTMD975-91Class2D”Thiscanonlybeusedif thefuelhasthecorrectspecificationoflubricity.

“JISK2204(1992)Grades1,2,3andSpecialGrade 3”Thiscanonlybeusedifthefuelhasthecorrect specificationoflubricity.

Note: Iflowsulfurorlowsulfuraromaticfuelsare used,thenfueladditivescanbeusedtoincrease lubricity.

Group2(permissiblefuels):Specification

Thesefuelspecificationsareconsideredacceptable forissuesofwarranty.However,thesefuelsmay reducethelifeoftheengine,theengine’smaximum powerandtheengine’sfuelefficiency.

“ASTMD975- 91Class1D”

“JP7,MilT38219”

“NATOF63”

NOTICE

Thesefuelsshouldhaveawearscarvalueof650 micrometersmaximum*HFRRtoISO12156-1.*

Group3(aviationkerosenefuels):Specification

Thesefuels needadditivestoachievelubricityof650 micrometerswearscarandthereliabilityofthefuel pumpandfuelinjectorswillbereduced.Thefuel injection pumpisnotcoveredbyawarranty,even whentheadditivesareincluded.

“JP5MILT5624(AvcatFSII,NATOF44”

“JP8T83133(AvturFSII,NATOF34”

“JetA”

“JetA1,NATOF35,XF63”

Lowtemperaturefuels

Specialfuelsforuseincoldweathermaybeavailable forengineoperationattemperaturesbelow0°C (32°F).Thesefuelslimittheformationofwaxinthe fueloilatlowtemperatures.Ifwaxformsinthefuel oil,thiscouldstoptheflowoffueloilthroughthefilter.

Note: Thesefuelsthatlacklubricitymaycausethe followingproblems:

• Lowenginepower

• Difficultstartinginhotconditionsorincold conditions

• Whitesmoke

• Deteriorationofemissionsandmisfireatcertain operatingconditions

Biofuel:Specification

Biofuel:A5%mixofRMEtoEN14214inconventional fuelispermitted.

NOTICE

Wateremulsionfuels:Thesefuelsarenotpermitted

Refertothefollowingfuelspecificationsfor NorthAmerica.

Thepreferredfuelsprovidemaximumengineservice lifeandperformance.Thepreferredfuelsaredistillate fuels.These fuelsarecommonlycalleddieselfuel orgasoil.

Thepermissiblefuelsarecrudeoilsorblendedfuels. Useofthesefuelscanresultinhighermaintenance costsandinreducedengineservicelife.

DieselfuelsthatmeetthespecificationsinTable 9willhelptoprovidemaximumengineservicelife andperformance.InNorthAmerica,dieselfuelthat isidentifiedasNo.2-Din“ASTMD975”generally meetsthespecifications.Table9isfordieselfuels thataredistilledfromcrudeoil.Dieselfuelsfrom othersourcescouldexhibitdetrimentalproperties thatarenotdefinedorcontrolledbythisspecification.

Table9

PerkinsSpecificationsforDistillateDieselFuel

Specifications Requirements

ASTMTest

Aromatics 35%maximum “D1319”

Ash 0.02%maximum (weight) “D482” (continued)

Table10

DistillateFuels (1) Specification

“MIL-T-5624R” JP-5

“ASTMD1655” Jet-A-1

“MIL-T-83133D” JP-8

(1) ThefuelsthatarelistedinthisTablemaynotmeetthe requirementsthatarespecifiedinthe“PerkinsSpecifications forDistillateDieselFuel”Table.Consultthesupplierforthe recommendedadditivesinordertomaintainthecorrectfuel lubricity.

ThesefuelsarelighterthantheNo.2gradesoffuel. ThecetanenumberofthefuelsinTable10mustbe atleast40.Iftheviscosityisbelow1.4cStat38°C (100°F),usethefuelonlyintemperaturesbelow 0°C(32°F).Donotuseanyfuelswithaviscosity oflessthan1.2cStat38°C(100°F).Fuelcooling mayberequiredinordertomaintaintheminimum viscosityof1.4cStatthefuelinjectionpump.

Therearemanyotherdieselfuelspecificationsthat arepublishedbygovernmentsandbytechnological societies.Usually,thosespecificationsdonot reviewalltherequirementsthatareaddressed inthisspecification.Toensureoptimumengine performance,acompletefuelanalysisshouldbe obtainedbeforeengineoperation.Thefuelanalysis shouldincludeallofthepropertiesthatarelistedin Table9.

CoolingSystemSpecifications

GeneralCoolantInformation

NOTICE

Neveraddcoolanttoanoverheatedengine.Engine damagecouldresult.Allowtheenginetocoolfirst.

NOTICE

Iftheengineistobestoredin,orshippedtoanarea withbelowfreezingtemperatures,thecoolingsystem mustbeeitherprotectedtothelowestoutsidetemperatureordrainedcompletelytopreventdamage.

NOTICE

Frequentlycheckthespecificgravityofthecoolantfor properfreezeprotectionorforanti-boilprotection.

Cleanthecoolingsystemforthefollowingreasons:

• Contaminationofthecoolingsystem

• Overheatingoftheengine

• Foamingofthecoolant

NOTICE

Neveroperateanenginewithoutwatertemperature regulatorsinthecoolingsystem.Watertemperature regulatorshelptomaintaintheenginecoolantatthe properoperatingtemperature.Coolingsystemproblemscandevelopwithoutwatertemperatureregulators.

Manyenginefailuresarerelatedtothecooling system.Thefollowingproblemsarerelatedtocooling systemfailures:Overheating,leakageofthewater pump,andpluggedradiatorsorheatexchangers.

Thesefailurescanbeavoidedwithcorrectcooling systemmaintenance.Coolingsystemmaintenanceis asimportantasmaintenanceofthefuelsystemand thelubricationsystem.Qualityofthecoolantisas importantasthequalityofthefuelandthelubricating oil.

Coolantisnormallycomposedofthreeelements: Water,additives,andglycol.

Water

Waterisusedinthecoolingsysteminorderto transferheat.

Distilledwaterordeionizedwateris recommendedforuseinenginecoolingsystems.

DONOTusethefollowingtypesofwaterincooling systems:Hardwater,softenedwaterthathasbeen conditionedwithsalt,andseawater.

Ifdistilledwaterordeionizedwaterisnotavailable, usewaterwiththepropertiesthatarelistedinTable 11.

Table11

AcceptableWater

Forawateranalysis,consultoneofthefollowing sources:

• Localwaterutilitycompany

• Agriculturalagent

• Independentlaboratory

Additives

Additiveshelptoprotectthemetalsurfacesof thecoolingsystem.Alackofcoolantadditivesor insufficientamountsofadditivesenablethefollowing conditionstooccur:

• Corrosion

• Formationofmineraldeposits

• Rust

• Scale

• Foamingofthe coolant

Manyadditivesaredepletedduringengineoperation. Theseadditivesmustbereplacedperiodically.

Additivesmustbeaddedatthecorrectconcentration. Overconcentrationofadditivescancausethe inhibitorstodropout-of-solution.Thedepositscan enablethefollowingproblemstooccur:

• Formationofgelcompounds

• Reductionof heattransfer

• Leakageofthewaterpumpseal

• Pluggingofradiators,coolers,andsmallpassages

Glycol

Glycolinthecoolanthelpstoprovideprotection againstthe followingconditions:

• Boiling

• Freezing

• Cavitation ofthewaterpump

Foroptimumperformance,Perkinsrecommendsa 1:1mixture ofawater/glycolsolution.

Note: Useamixturethatwillprovideprotection againstthe lowestambienttemperature.

Note: 100percentpureglycolwillfreezeata temperatureof 23°C( 9°F).

Mostconventionalantifreezesuseethyleneglycol. Propylene glycolmayalsobeused.Ina1:1mixture withwater,ethyleneandpropyleneglycolprovide similarprotectionagainstfreezingandboiling.See Tables12and13.

NOTICE

Donotusepropyleneglycolinconcentrationsthatexceed50percentglycolbecauseofpropyleneglycol’s reducedheattransfercapability.Useethyleneglycol inconditionsthatrequireadditionalprotectionagainst boilingorfreezing.

50Percent 29°C( 20°F)

Tochecktheconcentrationofglycolinthecoolant, measurethespecificgravityofthecoolant.

CoolantRecommendations

ThefollowingtwocoolantsareusedinPerkinsdiesel engines:

Preferred– PerkinsExtendedLifeCoolant(ELC)

Acceptable– Acommercialheavy-dutyantifreeze thatmeets“ASTMD4985”specifications

NOTICE

Donotuseacommercialcoolant/antifreezethatonlymeetstheASTMD3306specification.Thistypeof coolant/antifreezeismadeforlightautomotiveapplications.

Perkinsrecommendsa1:1mixtureofwaterand glycol.Thismixtureofwaterandglycolwillprovide optimumheavy-dutyperformanceasaantifreeze. Thisratiomaybeincreasedto1:2watertoglycolif extrafreezingprotectionisrequired.

Note: Acommercialheavy-dutyantifreezethat meets“ASTMD4985”specificationsMAYrequirea treatmentwithanSCAattheinitialfill.Readthelabel ortheinstructionsthatareprovidedbytheOEMof theproduct.

Table12

EthyleneGlycol

Table13

PropyleneGlycol

Afterthecoolingsystemisdrainedandafterthe coolingsystemisrefilled,operatetheenginewhile thecoolingsystemfillercapisremoved.Operate theengineuntilthecoolantlevelreachesthenormal operatingtemperatureanduntilthecoolantlevel stabilizes.Asneeded,addthecoolantmixturein ordertofill thesystemtothespecifiedlevel.

ChangingtoPerkinsELC

Tochangefromheavy-dutyantifreezetothePerkins ELC,performthefollowingsteps:

NOTICE

Caremustbetakentoensurethatallfluidsare containedduringperformanceofinspection,maintenance,testing,adjustingandtherepairofthe product.Bepreparedtocollectthefluidwithsuitable containersbeforeopeninganycompartmentordisassembling anycomponentcontainingfluids.

Disposeofallfluidsaccordingtolocalregulationsand mandates.

1. Drainthecoolantintoasuitablecontainer.

2. Disposeofthecoolantaccordingtolocal regulations.

3. Flushthesystemwithcleanwaterinorderto removeanydebris.

4. UsePerkins cleanertocleanthesystem.Follow theinstructiononthelabel.

5. Drainthecleanerintoasuitablecontainer.Flush thecoolingsystemwithcleanwater.

6. Fillthecoolingsystemwithcleanwaterand operatetheengineuntiltheengineiswarmedto 49°to66°C(120°to150°F).

NOTICE

Incorrectorincompleteflushingofthecoolingsystem canresultindamagetocopperandothermetalcomponents.

Toavoiddamagetothecoolingsystem,makesureto completelyflushthecoolingsystemwithclearwater. Continuetoflushthesystemuntilallthesignsofthe cleaningagentaregone.

7. Drainthecoolingsystemintoasuitablecontainer andflushthecoolingsystemwithcleanwater.

Note: Thecoolingsystemcleanermustbethoroughly flushedfromthecoolingsystem.Coolingsystem cleanerthatisleftinthesystemwillcontaminatethe coolant.Thecleanermayalsocorrodethecooling system.

8. RepeatSteps 6and7untilthesystemis completelyclean.

9. FillthecoolingsystemwiththePerkinsPremixed ELC.

ELCCoolingSystemContamination

NOTICE

MixingELCwithotherproductsreducestheeffectivenessoftheELCandshortenstheELCservicelife. UseonlyPerkinsProductsforpremixedorconcentratecoolants.Failuretofollowtheserecommendationscanresultinshortenedcoolingsystemcomponentlife.

ELCcoolingsystemscanwithstandcontaminationto amaximumoftenpercentofconventionalheavy-duty antifreezeorSCA.Ifthecontaminationexceedsten percentofthetotalsystemcapacity,performONEof thefollowingprocedures:

• Drainthecoolingsystemintoasuitablecontainer. Disposeofthecoolantaccordingtolocal regulations.Flushthesystemwithcleanwater.Fill thesystemwiththePerkinsELC.

• Drainaportionofthecoolingsystemintoasuitable containeraccordingtolocalregulations.Then,fill thecoolingsystemwithpremixedELC.Thisshould lowerthecontaminationtolessthan10percent.

• MaintainthesystemasaconventionalHeavy-Duty Coolant.TreatthesystemwithanSCA.Change thecoolantattheintervalthatisrecommendedfor theconventionalHeavy-DutyCoolant.

CommercialHeavy-DutyAntifreezeand SCA

NOTICE

CommercialHeavy-DutyCoolantwhichcontains Amineas partofthecorrisionprotectionsystemmust notbeused.

NOTICE

Neveroperateanenginewithoutwatertemperature regulatorsinthecoolingsystem.Watertemperature regulatorshelptomaintaintheenginecoolantatthe correctoperatingtemperature.Coolingsystemproblemscandevelopwithoutwatertemperatureregulators.

MaintenanceSection RefillCapacities

Checktheantifreeze(glycolconcentration)in ordertoensureadequateprotectionagainstboiling orfreezing.Perkinsrecommendstheuseofa refractometerforcheckingtheglycolconcentration.

Perkinsenginecoolingsystemsshouldbetested at500hourintervalsfortheconcentrationof SupplementalCoolantAdditive(SCA).

Additionsof SCAarebasedontheresultsofthetest. AnSCAthatisliquidmaybeneededat500hour intervals.

RefertoTable15forpartnumbersandforquantities ofSCA.

Table15

AddingtheSCAtoHeavy-DutyCoolant attheInitialFill

Commercialheavy-dutyantifreezethatmeets“ASTM D4985”specificationsMAYrequireanadditionof SCAattheinitialfill.Readthelabelortheinstructions thatareprovidedbytheOEMoftheproduct.

UsetheequationthatisinTable16todeterminethe amountofPerkinsSCAthatisrequiredwhenthe coolingsystemisinitiallyfilled.

Table16

EquationForAddingTheSCAToTheHeavy-Duty CoolantAtTheInitialFill

V×0.045=X

Visthetotalvolumeofthecoolingsystem. XistheamountofSCAthatisrequired.

Table17isanexampleforusingtheequationthat isinTable16.

Table17

ExampleOfTheEquationForAddingTheSCATo TheHeavy-DutyCoolantAtTheInitialFill

AddingTheSCAtoTheHeavy-Duty CoolantForMaintenance

Heavy-dutyantifreezeofalltypesREQUIREperiodic additionsofanSCA.

Testtheantifreezeperiodicallyfortheconcentration ofSCA.Fortheinterval,refertotheOperation andMaintenanceManual,“MaintenanceInterval Schedule”(MaintenanceSection).Testthe concentrationofSCA.

Additionsof SCAarebasedontheresultsofthe test.Thesizeofthecoolingsystemdeterminesthe amountofSCAthatisneeded.

UsetheequationthatisinTable18todeterminethe amountofPerkinsSCAthatisrequired,ifnecessary:

Table18

EquationForAddingTheSCAToTheHeavy-Duty CoolantForMaintenance

V×0.014=X

Visthetotalvolumeofthecoolingsystem. XistheamountofSCAthatisrequired.

Table19isanexampleforusingtheequationthat isinTable18.

Table19

ExampleOfTheEquationForAddingTheSCATo TheHeavy-DutyCoolantForMaintenance

CleaningtheSystemofHeavy-Duty Antifreeze

Perkinscoolingsystemcleanersaredesigned tocleanthecoolingsystemofharmfulscale andcorrosion.Perkinscoolingsystemcleaners dissolvemineralscale,corrosionproducts,lightoil contaminationandsludge.

• Cleanthecoolingsystemafterusedcoolantis drainedorbeforethecoolingsystemisfilledwith newcoolant.

• Cleanthecoolingsystemwheneverthecoolantis contaminatedorwheneverthecoolantisfoaming.

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AftercoolerCore-Clean/Test

1. Removethecore.RefertotheOEMinformation forthecorrectprocedure.

2. Turntheaftercoolercoreupside-downinorder toremovedebris.

Personalinjurycanresultfromairpressure.

Personalinjurycanresultwithoutfollowingproperprocedure.Whenusingpressureair,wearaprotectivefaceshieldandprotectiveclothing.

Maximumairpressureatthenozzlemustbeless than205kPa(30psi)forcleaningpurposes.

3. Pressurizedairisthepreferredmethodfor removingloosedebris.Directtheairinthe oppositedirectionofthefan’sairflow.Holdthe nozzleapproximately6mm(.25inch)awayfrom thefins.Slowlymovetheairnozzleinadirection thatisparallelwiththetubes.Thiswillremove debristhatisbetweenthetubes.

4. Pressurizedwatermayalsobeusedforcleaning. Themaximumwaterpressureforcleaning purposesmustbelessthan275kPa(40psi).Use pressurizedwaterinordertosoftenmud.Clean thecorefrombothsides.

NOTICE

Donotuseahighconcentrationofcausticcleanerto cleanthecore.Ahighconcentrationofcausticcleaner canattacktheinternalmetalsofthecoreandcause leakage.Onlyusetherecommendedconcentrationof cleaner.

5. Backflushthecorewithasuitablecleaner.

6. Steamcleanthecoreinordertoremoveany residue.Flushthefinsoftheaftercoolercore. Removeanyothertrappeddebris.

7. Washthecorewithhot,soapywater.Rinsethe corethoroughlywithcleanwater.

Personalinjurycanresultfromairpressure. Personalinjurycanresultwithoutfollowingproperprocedure.Whenusingpressureair,wearaprotectivefaceshieldandprotectiveclothing.

Maximumairpressureatthenozzlemustbeless than205kPa(30psi)forcleaningpurposes.

8. Drythecorewithcompressedair.Directtheairin thereversedirectionofthenormalflow.

9. Inspectthecoreinordertoensurecleanliness. Pressuretestthecore.Ifnecessary,repairthe core.

10. Installthecore.RefertotheOEMinformationfor thecorrectprocedure.

11. Aftercleaning,starttheengineandaccelerate theenginetohighidlerpm.Thiswillhelpinthe removalofdebrisanddryingofthecore.Stopthe engine.Usealightbulbbehindthecoreinorder toinspectthecoreforcleanliness.Repeatthe cleaning,ifnecessary.

AftercoolerCore-Inspect

i02322295

Note: Adjustthefrequencyofcleaningaccordingto theeffectsoftheoperatingenvironment.

Inspecttheaftercoolerfortheseitems:damagedfins, corrosion,dirt,grease,insects,leaves,oil,andother debris.Cleantheaftercooler,ifnecessary.

Forair-to-airaftercoolers,usethesamemethodsthat areusedforcleaningradiators.

Personal injurycanresultfromairpressure.

Personalinjurycanresultwithoutfollowingproperprocedure.Whenusingpressureair,wearaprotectivefaceshieldandprotectiveclothing.

Maximumairpressureatthenozzlemustbeless than205kPa(30psi)forcleaningpurposes.

Aftercleaning,starttheengineandacceleratethe enginetohighidlerpm.Thiswillhelpintheremoval ofdebrisanddryingofthecore.Stoptheengine. Usealightbulbbehindthecoreinordertoinspect thecoreforcleanliness.Repeatthecleaning,if necessary.

Inspectthefinsfordamage.Bentfinsmaybeopened witha“comb”.

Note: Ifpartsoftheaftercoolersystemarerepaired orreplaced,aleaktestishighlyrecommended.

Inspecttheseitemsforgoodcondition:Welds, mountingbrackets,airlines,connections,clamps, andseals.Makerepairs,ifnecessary.

Alternator-Inspect

Perkinsrecommendsascheduledinspectionof thealternator.Inspectthealternatorforloose connectionsandcorrectbatterycharging.Checkthe ammeter(ifequipped)duringengineoperationin ordertoensurecorrectbatteryperformanceand/or correctperformanceoftheelectricalsystem.Make repairs,asrequired.

Checkthealternatorandthebatterychargerfor correctoperation.Ifthebatteriesarecorrectly charged,theammeterreadingshouldbeverynear zero.Allbatteriesshouldbekeptcharged.The batteriesshouldbekeptwarmbecausetemperature affectsthecrankingpower.Ifthebatteryistoocold, thebatterywillnotcranktheengine.Whenthe engineisnotrunforlongperiodsoftimeorifthe engineisrunforshortperiods,thebatteriesmaynot fullycharge.Abatterywithalowchargewillfreeze moreeasilythanabatterywithafullcharge.

AlternatorBeltInspect/Adjust/Replace (PolyV-Belt) Inspection

Tomaximizetheengineperformance,inspectthebelt (1)forwearandforcracking.Replacethebeltifthe beltiswornordamaged.

• Ifthebelt(1)hasmorethanfourcracksper 25.4000mm(1inch)thebeltmustbereplaced.

• Checkthebeltofcracks,splits,glazing,grease, andsplitting.

Adjustment

Thistypeofbelthasanautomaticbelttensioner.

Replace

RefertoDisassemblyandAssemblymanual, “AlternatorBelt-RemoveandInstall”.

Battery-Replace

Batteriesgiveoffcombustiblegaseswhichcan explode.Asparkcancausethecombustiblegasestoignite.Thiscanresultinseverepersonalinjuryordeath.

Ensureproperventilationforbatteriesthatarein anenclosure.Followtheproperproceduresinordertohelppreventelectricalarcsand/orsparks nearbatteries.Donotsmokewhenbatteriesare serviced.

i02322311

i02491869

g01251375

i02322315

BatteryElectrolyteLevel-Check

Thebatterycablesorthebatteriesshouldnotbe removedwiththebatterycoverinplace.Thebatterycovershouldberemovedbeforeanyservicingisattempted.

Removingthebatterycablesorthebatterieswith thecoverinplacemaycauseabatteryexplosion resultinginpersonalinjury.

1. SwitchtheenginetotheOFFposition.Remove allelectricalloads.

2. Turnoffanybatterychargers.Disconnectany batterychargers.

3. TheNEGATIVE“-”cableconnectstheNEGATIVE “-”batteryterminaltotheNEGATIVE“-”terminal onthestartingmotor.Disconnectthecablefrom theNEGATIVE“-”batteryterminal.

4. ThePOSITIVE“+”cableconnectsthePOSITIVE “+”batteryterminaltothePOSITIVE“+”terminal onthestartingmotor.Disconnectthecablefrom thePOSITIVE“+”batteryterminal.

Note: Alwaysrecycleabattery.Neverdiscarda battery.Disposeofusedbatteriestoanappropriate recyclingfacility.

5. Removetheusedbattery.

6. Installthenewbattery.

Note: Beforethecablesareconnected,ensurethat theenginestartswitchisOFF.

7. Connectthecablefromthestartingmotortothe POSITIVE“+”batteryterminal.

8. ConnecttheNEGATIVE“-”cabletothe NEGATIVE“-”batteryterminal.

BatteryElectrolyteLevel-

Check

Whentheengineisnotrunforlongperiodsoftimeor whentheengineisrunforshortperiods,thebatteries maynotfullyrecharge.Ensureafullchargeinorder tohelppreventthebatteryfromfreezing.Ifbatteries arecorrectlycharged,theammeterreadingshould beverynearzero,whentheengineisinoperation.

Alllead-acidbatteriescontainsulfuricacidwhich canburntheskinandclothing.Alwayswearaface shieldandprotectiveclothingwhenworkingonor nearbatteries.

1. Removethefillercaps.Maintaintheelectrolyte leveltothe“FULL”markonthebattery.

Iftheadditionofwaterisnecessary,usedistilled water.Ifdistilledwaterisnotavailableuseclean waterthatislowinminerals.Donotuseartificially softenedwater.

2. Checktheconditionoftheelectrolytewitha suitablebatterytester.

3. Installthecaps.

4. Keepthebatteriesclean.

Cleanthebatterycasewithoneofthefollowing cleaningsolutions:

• Amixtureof0.1kg(0.2lb)ofwashingsodaor bakingsodaand1L(1qt)ofcleanwater

• Amixtureof0.1L(0.11qt)ofammoniaand1L (1qt)ofcleanwater

Thoroughlyrinsethebatterycasewithcleanwater.

BatteryorBatteryCableDisconnect

Thebatterycablesorthebatteriesshouldnotbe removedwiththebatterycoverinplace.Thebatterycover shouldberemovedbeforeanyservicingisattempted.

Removing thebatterycablesorthebatterieswith thecoverinplacemaycauseabatteryexplosion resultinginpersonalinjury.

1. TurnthestartswitchtotheOFFposition.Turnthe ignitionswitch(ifequipped)totheOFFposition andremovethekeyandallelectricalloads.

2. Disconnectthenegativebatteryterminal.Ensure thatthecablecannotcontacttheterminal.When four12voltbatteriesareinvolved,twonegative connectionmustbedisconnected.

i02322318

MaintenanceSection

CoolingSystemCoolant(ELC)-Change

Forinformationregardingthedisposalandthe recyclingofusedcoolant,consultyourPerkinsdealer oryourPerkinsdistributor.

Flush

1. Flushthecoolingsystemwithcleanwaterinorder toremoveanydebris.

2. Closethedraincockorinstallthedrainpluginthe engine.Closethedraincockorinstallthedrain plugontheradiator.

NOTICE

Donotfillthecoolingsystemfasterthan5L (1.3USgal)perminutetoavoidairlocks.

Coolingsystemairlocksmayresultinenginedamage.

3. Fillthecoolingsystemwithcleanwater.Installthe coolingsystemfillercap.

4. Startandruntheengineatlowidleuntilthe temperaturereaches49to66°C(120to150°F).

5. Stoptheengineandallowtheenginetocool. Loosenthecoolingsystemfillercapslowlyin ordertorelieveanypressure.Removethecooling systemfillercap.Openthedraincockorremove thedrainplugontheengine.Openthedraincock orremovethedrainplugontheradiator.Allow thewatertodrain.Flushthecoolingsystemwith cleanwater.

Fill

1. Closethedraincockorinstallthedrainplugon theengine.Closethedraincockorinstallthe drainplug ontheradiator.

NOTICE

Donotfillthecoolingsystemfasterthan5L (1.3USgal)perminutetoavoidairlocks.

Coolingsystemairlocksmayresultinenginedamage.

2. FillthecoolingsystemwithCommercial Heavy-DutyCoolant.AddSupplementalCoolant Additive tothecoolant.Forthecorrectamount, refertotheOperationandMaintenanceManual, “FluidRecommendations”topic(Maintenance Section) formoreinformationoncoolingsystem specifications.Donotinstallthecoolingsystem fillercap.

3. Startandruntheengineatlowidle.Increasethe enginerpmtohighidle.Runtheengineathigh idleforoneminuteinordertopurgetheairfrom thecavitiesoftheengineblock.Decreasethe enginespeedtolowidle.Stoptheengine.

4. Checkthecoolantlevel.Maintainthecoolantlevel within13mm(0.5inch)belowthebottomofthe pipeforfilling.Maintainthecoolantlevelinthe expansionbottle(ifequipped)atthecorrectlevel.

5. Cleanthecoolingsystemfillercapandinspectthe gasket.Ifthegasketisdamaged,discardtheold fillercapandinstallanewfillercap.Ifthegasket isnotdamaged,useasuitablepressurizingpump inordertopressuretestthefillercap.Thecorrect pressureisstampedonthefaceofthefillercap.If thefillercapdoesnotretainthecorrectpressure, installanewfillercap.

6. Starttheengine.Inspectthecoolingsystemfor leaksandforcorrectoperatingtemperature. i02490917

NOTICE

Caremustbetakentoensurethatfluidsarecontained duringperformanceofinspection,maintenance,testing,adjustingandrepairoftheproduct.Bepreparedto collectthefluidwithsuitablecontainersbeforeopeninganycompartmentordisassemblinganycomponentcontainingfluids.

DisposeofallfluidsaccordingtoLocalregulationsand mandates.

g00103639

Illustration29 Fillercap

NOTICE

Keepallpartscleanfromcontaminants.

Contaminantsmaycauserapidwearandshortened componentlife

Cleanthecoolingsystemandflushthecooling systembeforetherecommendedmaintenance intervalifthefollowingconditionsexist:

• Theengineoverheatsfrequently.

• Foamingofthecoolantisobserved.

• Theoilhasenteredthecoolingsystemandthe coolantiscontaminated.

• Thefuelhasenteredthecoolingsystemandthe coolantiscontaminated.

Note: Whenthecoolingsystemiscleaned,only cleanwaterisneededwhentheELCisdrainedand replaced.

Note: Inspectthewaterpumpandthewater temperatureregulatorafterthecoolingsystemhas beendrained.Thisisagoodopportunitytoreplace thewaterpump,thewatertemperatureregulatorand thehoses,ifnecessary.

Drain

PressurizedSystem:Hotcoolantcancauseseriousburns.Toopenthecoolingsystemfillercap, stoptheengineandwaituntilthecoolingsystem componentsarecool.Loosenthecoolingsystem pressurecapslowlyinordertorelievethepressure.

1. Stoptheengineandallowtheenginetocool. Loosenthecoolingsystemfillercapslowlyin ordertorelieveanypressure.Removethecooling systemfillercap.

2. Openthedraincockorremovethedrainplug(1) ontheengine.Openthedraincockorremovethe drainplugontheradiator.

Allowthecoolanttodrain.

NOTICE

Disposeofusedenginecoolantorrecycle.Various methodshavebeenproposedtoreclaimusedcoolant forreuseinenginecoolingsystems.Thefulldistillation procedureistheonlymethodacceptablebyPerkinsto reclaimthecoolant.

Forinformationregardingthedisposalandthe recyclingofusedcoolant,consultyourPerkinsdealer oryourPerkinsdistributor.

Flush

1. Flushthecoolingsystemwithcleanwaterinorder toremoveanydebris.

2. Closethedraincockorinstallthedrainpluginthe engine.Closethedraincockorinstallthedrain plugontheradiator.

NOTICE

Donotfillthecoolingsystemfasterthan5L (1.3USgal)perminutetoavoidairlocks.

Coolingsystemairlocksmayresultinenginedamage.

3. Fillthecoolingsystemwithcleanwater.Installthe coolingsystemfillercap.

g01244659

Illustration30 Typicalexample

4. Startandruntheengineatlowidleuntilthe temperaturereaches49to66°C(120to150°F).

Fill

1. Closethedraincockorinstallthedrainplugon theengine.Closethedraincockorinstallthe drainplugontheradiator.

NOTICE

Donotfillthecoolingsystemfasterthan5L (1.3USgal)perminutetoavoidairlocks.

Coolingsystemairlocksmayresultinenginedamage.

2. FillthecoolingsystemwithExtendedLife Coolant(ELC).RefertotheOperationand MaintenanceManual,“FluidRecommendations” topic(MaintenanceSection)formoreinformation oncoolingsystemspecifications.Donotinstallthe coolingsystemfillercap.

4. Checkthecoolantlevel.Maintainthecoolantlevel within13mm(0.5inch)belowthebottomofthe pipeforfilling.Maintainthecoolantlevelinthe expansionbottle(ifequipped)atthecorrectlevel.

6. Starttheengine.Inspectthecoolingsystemfor leaksandforcorrectoperatingtemperature.

CoolingSystemCoolantLevel -Check

EnginesWithaCoolantRecovery Tank

Note: Thecoolingsystemmaynothavebeen providedbyPerkins.Theprocedurethatfollows isfortypicalcoolingsystems.RefertotheOEM informationforthecorrectprocedures.

Checkthecoolantlevelwhentheengineisstopped andcool.

1. Observethecoolantlevelinthecoolantrecovery tank.Maintainthecoolantlevelto“COLDFULL” markonthecoolantrecoverytank.

2. Loosenfillercapslowlyinordertorelieveany pressure.Removethefillercap.

3. Pourthecorrectcoolantmixtureintothetank. RefertotheOperationandMaintenanceManual, “RefillCapacitiesandRecommendations”for informationonthecorrectmixtureandtypeof coolant.RefertotheOperationandMaintenance Manual,“RefillCapacitiesandRecommendations” forthecoolingsystemcapacity.Donotfillthe coolantrecoverytankabove“COLDFULL”mark.

4. Cleanfillercapandthereceptacle.Reinstallthe fillercapandinspectthecoolingsystemforleaks.

Note: Thecoolantwillexpandasthecoolantheats upduringnormalengineoperation.Theadditional volumewillbeforcedintothecoolantrecoverytank duringengineoperation.Whentheengineisstopped andcool,thecoolantwillreturntotheengine.

EnginesWithoutaCoolant RecoveryTank

Checkthecoolantlevelwhentheengineisstopped andcool.

2. Maintainthecoolantlevelwithin13mm(0.5inch) ofthebottomofthefillerpipe.Iftheengineis equippedwithasightglass,maintainthecoolant leveltothecorrectlevelinthesightglass.

3. Cleanthecoolingsystemfillercapandinspectthe gasket.Ifthegasketisdamaged,discardtheold fillercapandinstallanewfillercap.Ifthegasket isnotdamaged,useasuitablepressurizingpump inordertopressuretestthefillercap.Thecorrect pressureisstampedonthefaceofthefillercap.If thefillercapdoesnotretainthecorrectpressure, installanewfillercap.

4. Inspectthecoolingsystemforleaks.

g00285520

Coolingsystemcoolantadditivecontainsalkali. Tohelppreventpersonalinjury,avoidcontactwith theskinandtheeyes.Donotdrinkcoolingsystem coolantadditive.

TestforSCAConcentration

Heavy-DutyCoolant/AntifreezeandSCA

NOTICE

Donotexceedtherecommendedsixpercentsupplementalcoolantadditiveconcentration.

UseaCoolantConditionerTestKitinordertocheck theconcentrationoftheSCA.

Illustration33 Coolingsystemfillercap

1. Removethecoolingsystemfillercapslowlyin ordertorelievepressure.

CrankcaseBreather(Canister)-Replace

AddtheSCA,IfNecessary

NOTICE

Donotexceedtherecommendedamountofsupplementalcoolantadditiveconcentration.Excessive supplementalcoolantadditiveconcentrationcanform depositsonthehighertemperaturesurfacesofthe coolingsystem,reducingtheengine’sheattransfer characteristics.Reducedheattransfercouldcause crackingofthecylinderheadandotherhightemperaturecomponents.Excessivesupplementalcoolant additiveconcentrationcouldalsoresultinradiator tubeblockage,overheating,and/oracceleratedwater pumpsealwear.Neverusebothliquidsupplemental coolantadditiveandthespin-onelement(ifequipped) atthesametime.Theuseofthoseadditivestogether couldresultinsupplementalcoolantadditiveconcentrationexceedingtherecommendedmaximum.

Ensurethattheengineisstoppedbeforeanyservicing orrepairisperformed.

Note: Thebreatherassemblyisnotinstalledonall engines.

1. Placeacontainerunderthecanister(1).

2. Cleantheoutsideofthecanister.Useasuitable toolinordertoremovethecanister.

1. Slowlyloosenthecoolingsystemfillercapin ordertorelievethepressure.Removethecooling systemfillercap.

Note: Alwaysdiscarddrainedfluidsaccordingto localregulations.

2. Ifnecessary,drainsomecoolantfromthecooling systemintoasuitablecontainerinordertoallow spacefortheextraSCA.

3. AddthecorrectamountofSCA.Refertothe OperationandMaintenanceManual,“Refill CapacitiesandRecommendations”formore informationonSCArequirements.

4. Cleanthecoolingsystemfillercapandinspectthe gasket.Ifthegasketisdamaged,discardtheold fillercapandinstallanewfillercap.Ifthegasket isnotdamaged,useasuitablepressurizingpump inordertopressuretestthefillercap.Thecorrect pressureisstampedonthefaceofthefillercap.If thefillercapdoesnotretainthecorrectpressure, installanewfillercap.

Illustration34 Typicalexample

3. LubricatetheOringseal(2)onthenewcanister (3)withcleanenginelubricatingoil.Installthenew canister.Tightenthecanisterto12N·m(8lbft). Donotovertightenthecanister.

4. Removethecontainer.Disposeoftheoldcanister andanysplitoilinasafeplace.

i02151646

RefertotheOEMspecificationsformoreinformation onthefollowingmaintenancerecommendationsfor thedrivenequipment:

g01259960

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MaintenanceSection

EngineAirCleanerElement(DualElement)-Clean/Replace

Replacethedirtyaircleanerelementswithcleanair cleanerelements.Beforeinstallation,theaircleaner elementsshouldbethoroughlycheckedfortears and/orholesinthefiltermaterial.Inspectthegasket orthesealoftheaircleanerelementfordamage. Maintainasupplyofsuitableaircleanerelements forreplacementpurposes.

DualElementAirCleaners

Thedualelementaircleanercontainsaprimaryair cleanerelementandasecondaryaircleanerelement.

Theprimaryaircleanerelementcanbeusedup tosixtimesiftheelementisproperlycleanedand properlyinspected.Theprimaryaircleanerelement shouldbereplacedatleastonetimeperyear.This replacementshouldbeperformedregardlessofthe numberofcleanings.

Thesecondaryaircleanerelementisnotserviceable. RefertotheOEMinformationforinstructionsinorder toreplacethesecondaryaircleanerelement.

Whentheengineisoperatinginenvironmentsthat aredustyordirty,aircleanerelementsmayrequire morefrequentreplacement.

4. Cleantheinsideoftheaircleanercoverandbody withaclean,drycloth.

5. Removethetapefromtheairinlet.Installthe secondaryaircleanerelement.Installaprimary aircleanerelementthatisneworcleaned.

6. Installtheaircleanercover.

7. Resettheaircleanerserviceindicator.

CleaningthePrimaryAirCleaner Elements

RefertotheOEMinformationinordertodetermine thenumberoftimesthattheprimaryfilterelementcan becleaned.Whentheprimaryaircleanerelementis cleaned,checkforripsortearsinthefiltermaterial. Theprimaryaircleanerelementshouldbereplaced atleastone timeperyear.Thisreplacementshould beperformedregardlessofthenumberofcleanings.

NOTICE

Donottapor striketheaircleanerelement.

Donotwashtheprimaryaircleanerelement.

Uselowpressure(207kPa;30psimaximum)pressurisedairorvacuumcleaningtocleantheprimary aircleaner element.

Takeextremecareinordertoavoiddamagetotheair cleanerelements.

Donotuseaircleanerelementsthathavedamaged pleats,gasketsorseals.

Illustration35 (1)Cover (2)Primaryaircleanerelement (3)Secondaryaircleanerelement (4)Airinlet

1. Removethecover.Removetheprimaryair cleanerelement.

2. Thesecondaryaircleanerelementshouldbe removedanddiscardedforeverythreecleanings oftheprimaryaircleanerelement.

Note: Referto“CleaningthePrimaryAirCleaner Elements”.

3. Covertheairinletwithtapeinordertokeepdirt out.

RefertotheOEMinformationinordertodetermine thenumber oftimesthattheprimaryaircleaner elementcanbecleaned.Donotcleantheprimary airfilterelementmorethanthreetimes.Theprimary aircleanerelementmustbereplacedatleastone timeperyear.

Cleaningtheairfilterelementwillnotextendthelife oftheairfilterelement.

Visually inspecttheprimaryaircleanerelement beforecleaning.Inspectaircleanerelementsfor damagetothepleats,theseals,thegasketsand theouter cover.Discardanydamagedaircleaner element.

Twomethodsmaybeusedinordertocleanthe primaryaircleanerelement:

• pressurizedair

• Vacuumcleaning

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