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  SEBU8337-00 May 2008 Operation and Maintenance Manual 2206-E13 Industrial Engine TGB (Engine) TGD (Engine) TGF (Engine)
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  These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available. When replacement parts are required for this product Perkins recommends using Perkins replacement parts.

• Page 3: Table Of Contents

  SEBU8337 Table of Contents Table of Contents Warranty Section Warranty Information ……….82 Foreword …………..4 Index Section Safety Section Index …………..83 Safety Messages ………… 5 General Hazard Information ……..6 Burn Prevention …………7 Fire Prevention and Explosion Prevention ….8 Crushing Prevention and Cutting Prevention ..

• Page 4: Foreword

  They assist with developing the skills and Perkins authorized personnel. Your Perkins dealer techniques required to operate the engine more or your Perkins distributor offers a variety of options efficiently and economically. Skill and techniques regarding overhaul programs. If you experience…

• Page 5: Safety Section

  Replace any safety message that is damaged or missing. If a safety message is attached to a part of the engine that is replaced, install a new safety g00934493 Illustration 2 message on the replacement part. Your Perkins distributor can provide new safety messages.

• Page 6: General Hazard Information

  SEBU8337 Safety Section General Hazard Information Keep the engine free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps. Do not operate or work on this equipment unless you have read and understand the instructions Never put maintenance fluids into glass containers.

• Page 7: Burn Prevention

  SEBU8337 Safety Section Burn Prevention Coolant When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. Any contact with hot coolant or with steam can cause severe burns.

• Page 8: Fire Prevention And Explosion Prevention

  Personal injury, property damage, or engine damage could result. If the application involves the presence of combustible gases, consult your Perkins dealer and/or your Perkins distributor for additional information about suitable protection devices. Remove all flammable combustible materials or conductive materials such as fuel, oil, and debris from the engine.

• Page 9: Crushing Prevention And Cutting Prevention

  Do not clip any other items to the high pressure lines. Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks.

• Page 10: Mounting And Dismounting

  SEBU8337 Safety Section Mounting and Dismounting When objects are struck, wear protective glasses in If equipped, ensure that the lighting system for the order to avoid injury to the eyes. engine is suitable for the conditions. Ensure that all lights work correctly, if equipped. Chips or other debris may fly off objects when objects are struck.

• Page 11: Engine Stopping

  SEBU8337 Safety Section Engine Stopping Engine exhaust contains products of combustion Check the electrical wires daily for wires that which can be harmful to your health. Always start the are loose or frayed. Tighten all loose electrical engine and operate the engine in a well ventilated connections before the engine is started.

• Page 12: Engine Electronics

  SEBU8337 Safety Section Engine Electronics The power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery. i02773399 Engine Electronics Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine damage.

• Page 13: Product Information Section

  SEBU8337 Product Information Section General Information Product Information Section General Information i01889424 Welding on Engines with Electronic Controls NOTICE Proper welding procedures are necessary in order to avoid damage to the engine’s ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the compo- nent.

• Page 14: Model Views

  SEBU8337 Product Information Section Model Views Model Views i02770579 Model View Illustrations g01385634 Illustration 11 Typical example Left side engine view (1) Connection for the breather (4) Secondary fuel filter (7) Crankshaft damper (2) Electronic control module (ECM) (5) Primary fuel filter (8) Oil filler (3) Fuel priming pump (6) Fuel pump…

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  SEBU8337 Product Information Section Model Views g01385635 Illustration 12 Typical example Right side engine view (9) Water temperature regulator housing (12) Turbocharger (15) Oil cooler (10) Alternator (13) Oil filter (16) Exhaust manifold (11) Water pump (14) Oil drain plug The electronic engines that are covered by this i02770677 manual have the following characteristics: direct fuel…
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  DIAGNOSTIC lamp that is mounted on the control panel. An electronic service tool that is provided by Perkins may be used to read the diagnostic codes. These codes are logged and stored in the ECM. Refer to Operation and Maintenance Manual, “Engine Diagnostics”…

• Page 17: Product Identification Information

  Locations g01385686 Illustration 13 (1) Serial number plate Perkins engines are identified by serial numbers. These numbers are shown on the engine serial number plate. Perkins distributors need these numbers in order to determine the components that were included with the engine. This permits accurate…

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  SEBU8337 Product Information Section Product Identification Information Serial Number Plate (1) Total Lubrication System Capacity _________ ____________ Total Cooling System Capacity _________ ________________ Air Cleaner Element _________ ______________________________ Fan Drive Belt _________ _____________________________________ Alternator Belt _________ _____________________________________ g01403841 Illustration 14 Typical example The engine serial number plate is located on the right side of the engine block.
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  SEBU8337 Product Information Section Product Identification Information i02770895 Emissions Certification Film g01385765 Illustration 15 Typical example Programmable Monitoring System The emission certification film is located on the left hand side of the valve mechanism cover. (PMS) The Programmable Monitoring System determines i02817239 the level of action that is taken by the ECM in Customer Specified…
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  SEBU8337 Product Information Section Product Identification Information Table 2 Event Code Parameter State Trip Point Delay Time E162 High Boost Pressure 60 seconds Warn Operator (1) 300 kPa (43.5 psi) Action Alert (2) Always On 5 seconds E360 Low Engine Oil Pressure 60 seconds Warn Operator (1) 200 kPa (29 psi)

• Page 21: Operation Section

  Operation Section Lifting and Storage Operation Section i02848873 Product Storage Lifting and Storage Refer to Perkins Engine Company limited, Stafford for information on engine storage. i02513632 Product Lifting There is three different levels of engine storage. Level “A, B and C”.

• Page 22: Gauges And Indicators

  Determine and correct the cause of any significant change in the readings. Consult your Perkins distributor for assistance. NOTICE If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine.

• Page 23: Features And Controls

  If the engine is in the Warning condition, then the event will be logged in the memory of the ECM. A event code will be transmitted over the Perkins Data link and the hard wired Warning output will be The engine has protection in three stages: energized.

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  The ECM provides individual outputs in order to engine will be derated. The engine derate information drive warning lamps or relays to indicate each of the can be obtained from the Applications Department at following fault conditions: Perkins Engines Company Limited Stafford. • Diagnostic Fault Diagnostic •…
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  SEBU8337 Operation Section Features and Controls The Diagnostic output differs from the Warning and Shutdown outputs. The Warning and Shutdown outputs refer to the operation of the engine. The Diagnostic output refers to the condition of the electronic system and software system. A diagnostic fault may develop on the lubricating oil pressure or coolant temperature sensors.
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  SEBU8337 Operation Section Features and Controls g01386180 Illustration 17 (1) Engine coolant temperature sensor (4) Atmospheric pressure sensor (7) Fuel temperature sensor (2) Intake manifold pressure sensor (5) Secondary position sensor (Camshaft) (8) Primary position sensor (Crankshaft) (3) Intake manifold air temperature sensor (6) Engine oil pressure sensor (9) Electronic control module (ECM) Failure of Sensors…
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  SEBU8337 Operation Section Features and Controls Failure of the Coolant Temperature Low Oil Pressure Warning Sensor The setpoint for the low pressure warning is dependent upon the engine speed. The fault will be The ECM will detect a failure of the coolant active and logged only if the engine has been running temperature sensor.
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  SEBU8337 Operation Section Features and Controls Electronic Control Module 9 The ECM controls the engine operating parameters through the software within the ECM and the inputs from the various sensors. The software within the ECM can be changed by installing a new flash file. The flash file defines the following characteristics of the engine:Engine power, Torque curves, Engine speed (rpm), Engine Noise, Smoke, and Emissions.

• Page 29: Engine Diagnostics

  When the Electronic Control Module (ECM) have caused the lamp to light. generates an active diagnostic code, the code will be logged in the memory of the ECM. The Perkins • Low power electronic service tool can retrieve codes that have been logged.

• Page 30: Engine Starting

  1. Move the ignition switch to the ON position. If a system fault is indicated, investigate the cause. If necessary, use the Perkins electronic service tool. If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air 2.

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  2. Repeat step 1 three times if the engine fails to start. 3. If the engine fails to start, investigate the problem. Use the Perkins electronic service tool. A system fault may be indicated after the engine is started. If this occurs the ECM has detected a problem with the system.
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  SEBU8337 Operation Section Engine Starting i01646248 After Starting Engine Note: In temperatures from 0 to 60°C (32 to 140°F), the warm-up time is approximately three minutes. In temperatures below 0°C (32°F), additional warm-up time may be required. Note: Ensure that the self test for the monitoring system (if equipped) is completed before operating the engine under load.

• Page 33: Engine Operation

  Fuel Conservation Practices i02578030 Engine Operation The efficiency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures Correct operation and maintenance are key factors…

• Page 34: Engine Stopping

  SEBU8337 Operation Section Engine Stopping Engine Stopping i02583411 After Stopping Engine i02572824 Manual Stop Procedure Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. Stopping the Engine •…

• Page 35: Cold Weather Operation

  An electric block heater can be activated once have the ability to start readily. the engine is stopped. An effective block heater is typically a 1250/1500 W unit. Consult your Perkins • Install the correct specification of engine lubricant distributor for more information.

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  Fuel and the Effect from Cold Note: Group 3 fuels reduce the life of the engine. The Weather use of Group 3 fuels is not covered by the Perkins warranty. Group 3 fuels include Low Temperature Fuels and Aviation Kerosene Fuels.
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  SEBU8337 Operation Section Cold Weather Operation i02583420 Fuel Related Components in Cold Weather Fuel Tanks Condensation can form in partially filled fuel tanks. Top off the fuel tanks after you operate the engine. Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.

• Page 38: Maintenance Section

  SEBU8337 Maintenance Section Refill Capacities Maintenance Section i03040206 Fluid Recommendations Refill Capacities Cooling System Specifications i02793514 Refill Capacities General Coolant Information NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first. Lubrication System The refill capacities for the engine crankcase NOTICE reflect the approximate capacity of the crankcase…

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  • Cavitation of the water pump Property Maximum Limit Chloride (Cl) 40 mg/L For optimum performance, Perkins recommends a 1:1 mixture of a water/glycol solution. Sulfate (SO 100 mg/L Note: Use a mixture that will provide protection Total Hardness 170 mg/L against the lowest ambient temperature.
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  SEBU8337 Maintenance Section Refill Capacities Coolant Recommendations Extended Life Coolant (ELC) The following two coolants are used in Perkins diesel Perkins provides Extended Life Coolant (ELC) for engines: use in the following applications: • Preferred – Perkins Extended Life Coolant (ELC) Heavy-duty spark ignited gas engines •…
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  (SCA). can result in damage to copper and other metal com- ponents. When using Perkins ELC, do not use standard SCA’s or SCA filters. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water.
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  An SCA that is liquid may be needed at 500 hour intervals. Use the equation that is in Table 12 to determine the amount of Perkins SCA that is required, if necessary: Refer to Table 9 for part numbers and for quantities of SCA.
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  Clean the cooling system whenever the coolant is stated in table 14. contaminated or whenever the coolant is foaming. NOTICE i03040204 The footnotes are a key part of the Perkins Specifica- Fluid Recommendations tion for Distillate Diesel Fuel Table. Read ALL of the footnotes. (Fuel Specification) •…
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  SEBU8337 Maintenance Section Refill Capacities Table 14 Perkins Specification for Distillate Diesel Fuel Property UNITS Requirements “ASTM”Test “ISO”Test Aromatics %Volume 35% maximum D1319 “ISO”3837 %Weight 0.01% maximum D482 “ISO”6245 Carbon Residue on %Weight 0.35% maximum D524 “ISO”4262 10% Bottoms Cetane Number…
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  Regional regulations, national regulations or international regulations can require a fuel with a specific sulfur limit. Consult all applicable regulations before selecting a fuel for a given engine application. Perkins fuel systems and engine components can operate on high sulfur fuels.
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  Perkins recommends a value of density of 841 kg/m in order to obtain the correct power output. Lighter The lubricity has particular significance to the current…
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  SEBU8337 Maintenance Section Refill Capacities • “MIL-DTL-5624U NATO F44 (JP-5)” Table 15 Fuel Groups Classification • “MIL-DTL-38219D (USAF) F44 JP-7” Group 1 Preferred fuels Full life of the Product • “NATO F63” Group 2 Permissible These fuels • “NATO XF63” fuels with an MAY cause appropriate fuel…
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  Protection Agency (EPA) and European Certification This is especially true in engines with electronic fuels. Perkins does not certify engines on any other fuel systems because these engines operate at fuel. The user of the engine has the responsibility higher temperatures.
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  Maintenance Section Refill Capacities Fuel that complies with “EN590 ” CLASS 4 can be Perkins recognizes the fact that additives may used at temperatures as low as −44 °C (−47.2 °F). be required in some special circumstances. Fuel Refer to “EN590” for a detailed discretion of the additives need to be used with caution.
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  All DHD-1 oils must complete a full test program with the base stock and with the viscosity grade of The oil CD-2 is for a two-cycle diesel engine. Perkins does not sell engines that utilize CD-2 oil. the finished commercial oil. The use of “API Base Oil Interchange Guidelines”…
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  API CH-4 oils are recommended of these classifications: EMA DHD-1 and API CH-4. for conditions that demand a premium oil. Your Perkins dealer or your Perkins distributor has specific • Reduce the oil change interval. Base the oil guidelines for optimizing oil change intervals.
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  Re-refined base stock oils are acceptable for use in Perkins engines if these oils meet the Refer to Table 19 (maximum temperature) in order performance requirements that are specified by to select the oil viscosity for engine operation at the Perkins.
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  • Tests are conducted in order to detect contamination of the oil by water, glycol or fuel. Perkins does not recommend the use of aftermarket • additives in oil. It is not necessary to use aftermarket The Oil Condition Analysis determines the loss of additives in order to achieve the engine’s maximum…

• Page 54: Maintenance Interval Schedule

  SEBU8337 Maintenance Section Maintenance Interval Schedule Every 2000 Service Hours i02784638 Maintenance Interval Schedule Alternator — Inspect ……….55 Water Pump — Inspect ……….. 81 Every 3000 Service Hours or 2 Years When Required Cooling System Water Temperature Regulator — Battery — Replace ……….

• Page 55: Battery — Replace

  Aftercooler Core — Clean/Test Alternator — Inspect (Air-To-Air Aftercooler) Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose Note: Adjust the frequency of cleaning according to connections and correct battery charging. Check the the effects of the operating environment.

• Page 56: Battery Or Battery Cable — Disconnect

  SEBU8337 Maintenance Section Battery Electrolyte Level — Check 2. Turn off any battery chargers. Disconnect any 2. Check the condition of the electrolyte with a battery chargers. suitable battery tester. 3. The NEGATIVE “-” cable connects the NEGATIVE 3. Install the caps. “-”…

• Page 57: Every 500 Service Hours Belts — Inspect/Adjust/Replace

  SEBU8337 Maintenance Section Belts — Inspect/Adjust/Replace Alternator Belt Adjustment 5. Proceed with necessary system repairs. Reverse the steps in order to reconnect all of the cables. i02784753 Belts — Inspect/Adjust/Replace Inspection Inspect the alternator belt and the fan drive belts for wear and for cracking.

• Page 58: Every 6000 Service Hours Or 3 Years Cooling System Coolant (Elc) — Change

  SEBU8337 Maintenance Section Cooling System Coolant (ELC) — Change Adjustment of the Fan Drive Belt i02579635 Cooling System Coolant (ELC) — Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids.

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  filler cap. for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Perkins to 3. Start and run the engine for one minute in order reclaim the coolant.

• Page 60: Cooling System Coolant Level — Check

  Install” for the replacement procedure of the water level to the proper level in the sight glass. temperature regulator, or consult your Perkins distributor. Note: If only the water temperature regulators are…

• Page 61: Driven Equipment — Check

  • The temperature of the damper fluid is too high. component life. Refer to the Service Manual or consult your Perkins Only qualified service personnel should perform distributor for information about damper replacement. this maintenance. Refer to the following topics…

• Page 62: Engine — Clean

  NOT OPERATE”. Note: The air filter system may not have been NOTICE provided by Perkins. The procedure that follows Accumulated grease and oil on an engine is a fire haz- is for a typical air filter system. Refer to the OEM ard.

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  SEBU8337 Maintenance Section Engine Air Cleaner Element (Single Element) — Inspect/Replace NOTICE Do not tap or strike the air cleaner element. Do not wash the primary air cleaner element. Use low pressure (207 kPa; 30 psi maximum) pres- surised air or vacuum cleaning to clean the primary air cleaner element.

• Page 64: Engine Air Cleaner Service Indicator — Inspect

  SEBU8337 Maintenance Section Engine Air Cleaner Service Indicator — Inspect Inspect the clean, dry air cleaner element. Use a 60 Observe the service indicator. The air cleaner watt blue light in a dark room or in a similar facility. element should be cleaned or the air cleaner element Place the blue light in the air cleaner element.

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  SEBU8337 Maintenance Section Engine Crankcase Breather — Replace g01404604 Illustration 29 Typical example 2. Unlatch the clips (2) that secure the filter bowl (6). g01404613 Illustration 30 Typical example 3. Remove the filter bowl and remove the filter element (5). Remove the O ring seal (4) with the filter element.

• Page 66: Engine Oil Level — Check

  Note: The engine mounts may not have been supplied by Perkins. Refer to the OEM information 1. Maintain the oil level between the “Low” mark (Y) for further information on the engine mounts and the and the “High”…

• Page 67: Engine Oil Sample — Obtain

  Illustration 33 Illustration 34 Typical example Typical example Perkins recommends using a sampling valve in order NOTICE to obtain oil samples. The quality and the consistency Operating your engine when the oil level is above the of the samples are better when a sampling valve is “High”…

• Page 68: Engine Oil And Filter — Change

  SEBU8337 Maintenance Section Engine Oil and Filter — Change Ensure that the container for the sample is clean and After the oil has drained, the oil drain plug should be dry. Also ensure that the container for the sample is cleaned.

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  SEBU8337 Maintenance Section Engine Oil and Filter — Change NOTICE Do not fill the oil filters with oil before installing them. This oil would not be filtered and could be contaminat- ed. Contaminated oil can cause accelerated wear to engine components. 5.

• Page 70: Engine Protective Devices — Check

  Perkins distributor should perform the tests. g01394162 Illustration 38 Left side view Consult your Perkins distributor or refer to the Service (1) Secondary position sensor (Camshaft ) Manual for more information. (2) Primary position sensor (Crankshaft) 1. Remove the sensors from the front housing.

• Page 71: Fuel System — Prime

  NOTICE Only qualified service personel should perform this maintenance. Refer to the Service Manual or your au- thorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure. Operation of Perkins engines with incorrect valve lash g01395016 Illustration 39 can reduce engine efficiency, and also reduce engine…

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  SEBU8337 Maintenance Section Fuel System Primary Filter/Water Separator — Drain 10. Run the engine with no load until the engine runs smoothly. i02792791 Fuel System Primary Filter/Water Separator — Drain Fuel leaked or spilled onto hot surfaces or elec- trical components can cause a fire. To help pre- vent possible injury, turn the start switch off when changing fuel filters or water separator elements.

• Page 73: Fuel System Primary Filter/Water Separator

  SEBU8337 Maintenance Section Fuel System Primary Filter (Water Separator) Element — Replace NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over discon- nected fuel system component.

• Page 74: Fuel System Secondary Filter — Replace

  SEBU8337 Maintenance Section Fuel System Secondary Filter — Replace 7. Install the bowl assembly. Tighten the assembly to a torque of 80 N·m (59 lb ft). 8. Remove the container and dispose of the fuel safely. Turn the fuel supply valve (if equipped) to the ON position.

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  SEBU8337 Maintenance Section Fuel System Secondary Filter — Replace Note: The filter element for the secondary fuel filter is different from the element for the primary fuel filter. Ensure that the correct elements are installed into the fuel system. 4. Ensure that the insert (4) is the same shape as the tab (3).

• Page 76: Drain

  SEBU8337 Maintenance Section Fuel Tank Water and Sediment — Drain Some fuel tanks use supply pipes that allow water i02568194 and sediment to settle below the end of the fuel Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that — Drain take fuel directly from the bottom of the tank.

• Page 77: Jacket Water Heater — Check

  SEBU8337 Maintenance Section Jacket Water Heater — Check • Outer covering that is chafed or cut 7. Install the hose clamps. • Exposed wire that is used for reinforcement 8. Refill the cooling system. • Outer covering that is ballooning locally 9.

• Page 78: Severe Service Application — Check

  The following text describes a typical cleaning procedure for the radiator. For information on Severe service is the application of an engine that equipment that is not supplied by Perkins, refer to exceeds the current published standards for that the OEM.

• Page 79: Turbocharger — Inspect

  Note: Turbocharger components require precision clearances. The turbocharger cartridge must be balanced due to high rpm. Severe Service Perkins recommends a scheduled inspection of the Applications can accelerate component wear. starting motor. If the starting motor fails, the engine Severe Service Applications require more frequent may not start in an emergency situation.

• Page 80: Walk-Around Inspection

  For the removal of water pumps and the installation of water pumps and/or seals, refer to the Service Manual for the engine or consult your Perkins distributor. • Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters and the valve cover.

• Page 81: Water Pump — Inspect

  Inspect the fuel system for leaks. Look for loose Note: Refer to the Service Manual or consult your fuel line clamps or for loose fuel line tie-wraps. Perkins distributor if any repair is needed or any replacement is needed. •…

• Page 82: Warranty Section

  Emissions Warranty. Consult your authorized Perkins dealer or your authorized Perkins distributor in order to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty.

• Page 83: Index

  Battery — Replace……….. 55 Open Breather ……….. 66 Battery Electrolyte Level — Check ……56 Engine Description ……….15 Aftermarket Products and Perkins Engines ..16 Battery or Battery Cable — Disconnect ….56 Before Starting Engine ……..10, 30 Engine Diagnostics……….29 Engine Electronics……….

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  SEBU8337 Index Section Manual Stop Procedure……… 34 Foreword …………..4 California Proposition 65 Warning ……. 4 Emergency Stopping………. 34 Literature Information……….. 4 Stopping the Engine……….. 34 Maintenance …………4 Model View Illustrations……… 14 Maintenance Intervals………. 4 Model Views …………14 Monitoring System……….
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  SEBU8337 Index Section Sensors and Electrical Components ….. 25 Atmospheric Pressure Sensor 4 ……27 Electronic Control Module 9……. 28 Engine Coolant Temperature Sensor 1….26 Engine Oil Pressure Sensor 6……27 Failure of Sensors……….26 Fuel Temperature Sensor 7 ……. 27 Intake Manifold Air Temperature Sensor 3..
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  SEBU8337 Index Section…
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  Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:…
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  Copyright © 2008 Perkins Engines Company Limited A ll R i ght s R es er ve d Printed in U.K.

Foreword

Literature Information

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

English is the primary language for all Perkins publications. The English used facilitates translation and consistency.

Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Perkins dealer or your Perkins distributor for the latest available information.

Safety

This safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before

operating or performing lubrication, maintenance and repair on this product.

Operation

Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities.

The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.

Maintenance

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

Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of the original requirement. We recommend that the

maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine’s permanent record.

Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.

Overhaul

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that

interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your Perkins distributor offers a variety of options regarding overhaul programs. If you experience

a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Safety Section

i02767956

Safety Messages

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death.

Coolant

Very high injection pressures are produced by electronically controlled, mechanically actuated unit injectors. The injectors combine the pumping and the electronic fuel metering (duration and timing) during injection. The unit injectors accurately control smoke limiting, white smoke, and engine acceleration rates.

Engine efficiency, efficiency of emission controls, and engine performance depend on adherence to proper operation and maintenance recommendations. This includes the use of recommended fuels, coolants and lubrication oils.

The timing advance is achieved through precise control of the injector firing. Engine speed is controlled by adjusting the firing duration. The information is provided to the Electronic Control Module (ECM) by the crankshaft position sensor and the camshaft position sensor. The information is for detection of cylinder position and engine speed.

The engines have built-in diagnostics in order to ensure that all of the components are functioning and operating properly. In the event of a system component deviation from the programmed limits, the operator will be alerted to the condition by a DIAGNOSTIC lamp that is mounted on the control panel. An electronic service tool that is provided by Perkins may be used to read the diagnostic codes. These codes are logged and stored in the ECM. Refer to Operation and Maintenance Manual, “Engine Diagnostics” for additional information.

The cooling system consists of the following items: a centrifugal pump that is driven by a gear, water temperature regulator, an oil cooler, and a radiator that incorporates a shunt system.

The engine lubricating oil is supplied by a gear type pump. The engine lubricating oil is cooled and filtered. Bypass valves provide unrestricted flow of lubrication oil to the engine parts when the oil viscosity is high or if either the oil cooler or the oil filter elements (paper cartridge) become plugged.

Serial Number Plate (1)

The engine serial number plate is located on the right side of the engine block.

Engine serial number _____________________________________

Designation _________________________________________________

Engine Rating ______________________________________________

i02563635

Reference Numbers

Information for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Make a copy of this list for a record. Keep the information for future reference.

Record for Reference

Engine Model _______________________________________________

Engine Serial number _____________________________________

Engine rpm __________________________________________________

Primary Fuel Filter _________________________________________

Secondary Fuel Filter Element __________________________

Lubrication Oil Filter Element ___________________________

i02770895

Emissions Certification Film

Operation Section

Lifting and Storage

•Measured reading of the sensor is out of the specification.