Operation and Maintenance Manual: 854F-E34TA Industrial Engine

SEBU9068
February 2015
Operation and
Maintenance
Manual
854F-E34TA Industrial Engine
JU (Engine)
This document has been printed from SPI2. NOT FOR RESALE
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

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

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
SEBU9068 3
Table of Contents
Table of Contents Maintenance Section
Foreword.............................. ............................. 4 Refill Capacities....................... ....................... 60
Maintenance Recommendations.......... .......... 75

Safety Section
Maintenance Interval Schedule ........... ........... 78
Safety Messages....................... ....................... 5
General Hazard Information ............... .............. 5

Warranty Section
Burn Prevention........................ ........................ 9 Warranty Information .................. ...................110
Fire Prevention and Explosion Prevention ... .. 10 Reference Information Section
Crushing Prevention and Cutting Prevention . 12 Reference Materials ................... ...................111
Mounting and Dismounting............... .............. 13 Index Section
High Pressure Fuel Lines ................ ............... 13 Index............................... ...............................114
Before Starting Engine ................. .................. 14
Engine Starting ........................ ....................... 15
Engine Stopping ....................... ...................... 15
Electrical System ...................... ...................... 15
Engine Electronics..................... ..................... 17
Product Information Section
General Information.................... .................... 18
Product Identification Information.......... ......... 24
Operation Section
Lifting and Storage..................... ..................... 26
Features and Controls .................. .................. 29
Engine Diagnostics..................... .................... 45
Engine Starting ........................ ....................... 49
Engine Operation...................... ...................... 52
Cold Weather Operation................. ................ 54
Engine Stopping ....................... ...................... 58
4 SEBU9068
Foreword
Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
This manual contains safety, operation instructions, wet or freezing cold operating conditions, more
lubrication and maintenance information. This manual frequent lubrication and maintenance than is
should be stored in or near the engine area in a specified in the Maintenance Interval Schedule may
literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for a
preventive maintenance management program. If the
English is the primary language for all Perkins preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing Maintenance Intervals
improvement and advancement of product design
may have caused changes to your engine which are Perform maintenance on items at multiples of the
not included in this manual. Whenever a question original requirement. We recommend that the
arises regarding your engine, or this manual, please maintenance schedules be reproduced and displayed
consult with your Perkins dealer or your Perkins near the engine as a convenient reminder. We also
distributor for the latest available information. recommend that a maintenance record be maintained
as part of the engine's permanent record.
Safety Your authorized Perkins dealer or your Perkins
This safety section lists basic safety precautions. In distributor can assist you in adjusting your
addition, this section identifies hazardous, warning maintenance schedule to meet the needs of your
situations. Read and understand the basic operating environment.
precautions listed in the safety section before
operating or performing lubrication, maintenance and Overhaul
repair on this product.
Major engine overhaul details are not covered in the
Operation Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs should only be carried out by Perkins
Operating techniques outlined in this manual are authorized personnel. Your Perkins dealer or your
basic. They assist with developing the skills and Perkins distributor offers a variety of options
techniques required to operate the engine more regarding overhaul programs. If you experience a
efficiently and economically. Skill and techniques major engine failure, there are also numerous after
develop as the operator gains knowledge of the failure overhaul options available. Consult with your
engine and its capabilities.
Perkins dealer or your Perkins distributor for
The operation section is a reference for operators. information regarding these options.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating California Proposition 65 Warning
and stopping the engine. This section also includes a
discussion of electronic diagnostic information. 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
Maintenance posts, terminals and related accessories contain lead
The maintenance section is a guide to engine care. and lead compounds. Wash hands after handling.
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.
SEBU9068 5
Safety Section
Safety Messages
Safety Section
i05835940
Safety Messages
There may be several specific warning signs on your

engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become familiar with all warning signs.
Ensure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if the
words cannot be read or if the illustrations are not
visible. Use a cloth, water, and soap to clean the
warning signs. Do not use solvents, gasoline, or other
harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning signs. The warning signs that are loosened
could drop off the engine.
Replace any warning sign that is damaged or Illustration 2 g03373747
missing. If a warning sign is attached to a part of the Typical example
engine that is replaced, install a new warning sign on
the replacement part. Your Perkins distributor can
i06078546
provide new warning signs.
Universal Warning General Hazard Information
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.
Illustration 3 g00104545
Attach a “Do Not Operate” warning tag or a similar

warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. Attach the warning tags to the engine and to
each operator control station. When appropriate,
disconnect the starting controls.
Illustration 1 g01154807 Do not allow unauthorized personnel on the engine,

or around the engine when the engine is being
Typical example
serviced.
The Universal Warning label (1) is located on the top
of the engine, on the engine interface connector
cover.
6 SEBU9068
Safety Section
General Hazard Information
• Tampering with the engine installation or tampering • The engine is stopped. Ensure that the engine
with the OEM supplied wiring can be dangerous. cannot be started.
Personal injury, death and/or engine damage
could result. • The protective locks or the controls are in the
applied position.
• Vent the engine exhaust to the outside when the
engine is operated in an enclosed area. • Engage the secondary brakes or parking brakes.
• If the engine is not running, do not release the • Block the vehicle or restrain the vehicle before
secondary brake or the parking brake systems maintenance or repairs are performed.
unless the vehicle is blocked or unless the vehicle
is restrained. • Disconnect the batteries when maintenance is
performed or when the electrical system is
• Wear a hard hat, protective glasses, and other serviced. Disconnect the battery ground leads.
protective equipment, as required. Tape the leads in order to help prevent sparks. If
equipped, allow the diesel exhaust fluid to be
• When work is performed around an engine that is purged before disconnecting the battery.
operating, wear protective devices for ears in order
to help prevent damage to hearing. • If equipped, disconnect the connectors for the unit
injectors that are located on the valve cover base.
• Do not wear loose clothing or jewelry that can snag This action will help prevent personal injury from
on controls or on other parts of the engine. the high voltage to the unit injectors. Do not come
in contact with the unit injector terminals while the
• Ensure that all protective guards and all covers are engine is operating.
secured in place on the engine.
• Do not attempt any repairs or any adjustments to
• Never put maintenance fluids into glass the engine while the engine is operating.
containers. Glass containers can break.
• Do not attempt any repairs that are not
• Use all cleaning solutions with care. understood. Use the proper tools. Replace any
equipment that is damaged or repair the
• Report all necessary repairs. equipment.
Unless other instructions are provided, perform the • For initial start-up of a new engine or for starting an
maintenance under the following conditions:
engine that has been serviced, make provisions to
stop the engine if an overspeed occurs. The
stopping of the engine may be accomplished by
shutting off the fuel supply and/or the air supply to
the engine. Ensure that only the fuel supply line is
shut off. Ensure that the fuel return line is open.
• Start the engine from the operators station (cab).

Never short across the starting motor terminals or
the batteries. This action could bypass the engine
neutral start system and/or the electrical system
could be damaged.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
SEBU9068 7
Safety Section
• Filler caps • The engine is stopped. Ensure that the engine

cannot be started.
• Grease fittings
• Disconnect the batteries when maintenance is
• Pressure taps performed or when the electrical system is
serviced. Disconnect the battery ground leads.
• Breathers Tape the leads in order to help prevent sparks.
• Drain plugs • Do not attempt any repairs that are not
Use caution when cover plates are removed. understood. Use the proper tools. Replace any
Gradually loosen, but do not remove the last two bolts equipment that is damaged or repair the
or nuts that are located at opposite ends of the cover equipment.
plate or the device. Before removing the last two bolts
or nuts, pry the cover loose in order to relieve any Pressurized Air and Water
spring pressure or other pressure.
Pressurized air and/or water can cause debris and/or
hot water to be blown out. This action could result in
personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum water
pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
Illustration 4 g00702020 after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
• Wear a hard hat, protective glasses, and other escape rapidly if the pressure is not relieved correctly.
protective equipment, as required.
Do not remove any hydraulic components or parts
• When work is performed around an engine that is until pressure has been relieved or personal injury
operating, wear protective devices for ears in order may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
to help prevent damage to hearing. or personal injury may occur. Refer to the OEM
• Do not wear loose clothing or jewelry that can snag information for any procedures that are required to
relieve the hydraulic pressure.
on controls or on other parts of the engine.
• Ensure that all protective guards and all covers are
secured in place on the engine.
• Never put maintenance fluids into glass
containers. Glass containers can break.
• Use all cleaning solutions with care.

• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
8 SEBU9068
Safety Section
Avoid static electricity risk when fueling. Ultra-low

sulfur diesel fuel (ULSD fuel) poses a greater stat-
ic ignition hazard than earlier diesel formulations
with a higher sulfur contents. Avoid death or seri-
ous injury from fire or explosion. Consult with
your fuel or fuel system supplier to ensure the de-
livery system is in compliance with fueling stand-
ards for proper grounding and bonding practices.
Inhalation
Always use a board or cardboard when you check for

a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage

Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
product. Be prepared to collect the fluid with suitable Illustration 6 g00702022
containers before opening any compartment or
disassembling any component containing fluids.
Exhaust
Dispose of all fluids according to local regulations and
mandates. Use caution. Exhaust fumes can be hazardous to
health. If you operate the equipment in an enclosed
Static Electricity Hazard when area, adequate ventilation is necessary.
Fueling with Ultra-low Sulfur Diesel Asbestos Information
Fuel
Perkins equipment and replacement parts that are
The removal of sulfur and other compounds in ultra- shipped from Perkins engine company limited are
low sulfur diesel fuel (ULSD fuel) decreases the asbestos free. Perkins recommends the use of only
conductivity of ULSD and increases the ability of genuine Perkins replacement parts. Use the following
ULSD to store static charge. Refineries may have guidelines when you handle any replacement parts
treated the fuel with a static dissipating additive. that contain asbestos or when you handle asbestos
Many factors can reduce the effectiveness of the debris.
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel Use caution. Avoid inhaling dust that might be
delivery systems. Static electricity discharge when generated when you handle components that contain
combustible vapors are present could result in a fire asbestos fibers. Inhaling this dust can be hazardous
or explosion. Ensure that the entire system used to to your health. The components that may contain
refuel your machine (fuel supply tank, transfer pump, asbestos fibers are brake pads, brake bands, lining
transfer hose, nozzle, and others) is properly material, clutch plates, and some gaskets. The
grounded and bonded. Consult with your fuel or fuel asbestos that is used in these components is usually
system supplier to ensure that the delivery system bound in a resin or sealed in some way. Normal
complies with fueling standards for proper grounding handling is not hazardous unless airborne dust that
and bonding. contains asbestos is generated.
If dust that may contain asbestos is present, there are
several guidelines that should be followed:
SEBU9068 9
Safety Section
Burn Prevention
• Never use compressed air for cleaning. Diesel Exhaust Fluid

• Avoid brushing materials that contain asbestos. Diesel Exhaust Fluid (DEF) may cause eye irritation
and can be moderately irritating to the skin. Exposure
• Avoid grinding materials that contain asbestos. to decomposition products may cause a health
hazard. Serious effects may be delayed following
• Use a wet method in order to clean up asbestos exposure.
materials.
DEF is not expected to produce significant adverse
• A vacuum cleaner that is equipped with a high health effects when the recommended instructions for
use are followed.
efficiency particulate air filter (HEPA) can also be
used. • Do not breathe DEF vapor or mist.
• Use exhaust ventilation on permanent machining • Do not eat, drink, or smoke when using DEF.
jobs.
• Avoid DEF contact with eyes, skin, and clothing.
• Wear an approved respirator if there is no other
way to control the dust. • Wash thoroughly after handling DEF.
• Comply with applicable rules and regulations for
i06078513
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements Burn Prevention
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of Do not touch any part of an operating engine system.
asbestos. The engine, the exhaust, and the engine
aftertreatment system can reach temperatures as
• Stay away from areas that might have asbestos high as 650° C (1202° F) under normal operating
particles in the air. conditions.
Dispose of Waste Properly Allow the engine system to cool before any
maintenance is performed. Relieve all pressure in the
air system, hydraulic system, lubrication system, fuel
system, and the cooling system before the related
items are disconnected.
Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
After the engine has stopped, wait for 10 minutes in

order to allow the fuel pressure to be purged from the
Illustration 7 g00706404 high-pressure fuel lines before any service or repair is
performed on the engine fuel lines. The 10 minute
Improperly disposing of waste can threaten the wait will also allow static charge to dissipate from the
environment. Potentially harmful fluids should be low-pressure fuel system.
disposed of according to local regulations.
Allow the pressure to be purged in the air system, in
Always use leakproof containers when you drain the hydraulic system, in the lubrication system, or in
fluids. Do not pour waste onto the ground, down a the cooling system before any lines, fittings, or related
drain, or into any source of water. items are disconnected.
10 SEBU9068
Safety Section
Fire Prevention and Explosion Prevention
Induction System Batteries

Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for
Sulfuric Acid Burn Hazard may cause serious per- servicing batteries. Wash hands after touching the
sonal injury or death. batteries and connectors. Use of gloves is
recommended.
The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sulfur Aftertreatment System
levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid Allow the aftertreatment to cool down before any
may spill from the cooler during service of the en- maintenance or repair is performed.
gine. The sulfuric acid will burn the eyes, skin and
clothing on contact. Always wear the appropriate
personal protective equipment (PPE) that is noted Aftertreatment System and Diesel
on a material safety data sheet (MSDS) for sulfuric Exhaust Fluid
acid. Always follow the directions for first aid that
are noted on a material safety data sheet (MSDS) Diesel Exhaust Fluid (DEF) temperatures can reach
for sulfuric acid. 65° to 70°C (149.° to 126°F) during normal engine
operation. Stop the engine. Wait for 15 minutes in
order to allow the DEF system to be purged and the
Coolant DEF to cool before service or repair is performed.
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under i05670934
pressure. The radiator and all lines to the heaters,
aftertreatment system or to the engine contain hot Fire Prevention and Explosion
coolant.
Prevention
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check that the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Skin may be irritated following repeated or prolonged
exposure to mineral and synthetic base oils. Refer to Illustration 8 g00704000
your suppliers Material Safety Data Sheets for
detailed information. Hot oil and lubricating All fuels, most lubricants, and some coolant mixtures
components can cause personal injury. Do not allow are flammable.
hot oil to contact the skin. Appropriate personal
protective equipment should be used. Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
Diesel Fuel fire. Fire may cause personal injury and property
damage.
Diesel may be irritating to the eyes, respiratory
system, and skin. Prolonged exposure to diesel may After the emergency stop button is operated, ensure
cause various skin conditions. Appropriate personal that you allow 15 minutes, before the engine covers
protective equipment should be used. Refer to are removed.
supplier Material safety Data sheets for detailed
information.
SEBU9068 11
Safety Section
Fire Prevention and Explosion Prevention
Determine whether the engine will be operated in an After the engine has stopped, you must wait for 10
environment that allows combustible gases to be minutes in order to allow the fuel pressure to be
drawn into the air inlet system. These gases could purged from the high-pressure fuel lines before any
cause the engine to overspeed. Personal injury, service or repair is performed on the engine fuel lines.
property damage, or engine damage could result. The 10 minute wait will also allow static charge to
dissipate from the low-pressure fuel system.
If the application involves the presence of
combustible gases, consult your Perkins dealer and/ Ensure that the engine is stopped. Inspect all lines
or your Perkins distributor for additional information and hoses for wear or for deterioration. Ensure that
about suitable protection devices. the hoses are correctly routed. The lines and hoses
must have adequate support and secure clamps.
Remove all flammable combustible materials or
conductive materials such as fuel, oil, and debris from Oil filters and fuel filters must be correctly installed.
the engine. Do not allow any flammable combustible The filter housings must be tightened to the correct
materials or conductive materials to accumulate on torque. Refer to the Disassembly and Assembly
the engine. manual for more information.
Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line, a
tube, or a seal failure. Exhaust shields must be
installed correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Ensure that all
electrical wires are correctly installed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten all
electrical connections.
Eliminate all wiring that is unattached or unnecessary. Use caution when you are refueling an engine. Do not
Do not use any wires or cables that are smaller than smoke while you are refueling an engine. Do not
the recommended gauge. Do not bypass any fuses refuel an engine near open flames or sparks. Always
and/or circuit breakers. stop the engine before refueling.
Arcing or sparking could cause a fire. Secure Avoid static electricity risk when fueling. Ultra-low
connections, recommended wiring, and correctly Sulfur Diesel fuel (ULSD fuel) poses a greater static
maintained battery cables will help to prevent arcing ignition hazard than earlier diesel formulations with a
or sparking. higher sulfur content. Avoid death or serious injury
from fire or explosion. Consult your fuel or fuel system
supplier to ensure that the delivery system is in
compliance with fueling standards for proper
grounding and bonding practices.
12 SEBU9068
Safety Section
Crushing Prevention and Cutting Prevention
Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are
damaged.
Leaks can cause fires. Consult your Perkins dealer or
your Perkins distributor for replacement parts.
Replace the parts if any of the following conditions
are present:
• High-pressure fuel line or lines are removed.
• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.
• Wires are exposed.

• Outer coverings are ballooning.
• Flexible parts of the hoses are kinked.

Illustration 10 g00704135 • Outer covers have embedded armoring.
Gases from a battery can explode. Keep any open • End fittings are displaced.
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas. Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation,
Never check the battery charge by placing a metal correct installation will help to prevent vibration,
object across the terminal posts. Use a voltmeter or a rubbing against other parts, and excessive heat.
hydrometer.
Incorrect jumper cable connections can cause an i02143194
explosion that can result in injury. Refer to the
Operation Section of this manual for specific Crushing Prevention and
instructions.
Cutting Prevention
Do not charge a frozen battery. A frozen battery may
cause an explosion.
The batteries must be kept clean. The covers (if Support the component correctly when work beneath
equipped) must be kept on the cells. Use the the component is performed.
recommended cables, connections, and battery box
covers when the engine is operated. Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Fire Extinguisher
Stay clear of all rotating parts and of all moving parts.
Make sure that a fire extinguisher is available. Be Leave the guards in place until maintenance is
familiar with the operation of the fire extinguisher. performed. After the maintenance is performed,
Inspect the fire extinguisher and service the fire reinstall the guards.
extinguisher regularly. Obey the recommendations on
the instruction plate. Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
Ether
When objects are struck, wear protective glasses in
Ether is flammable and poisonous. order to avoid injury to the eyes.
Do not smoke while you are replacing an ether Chips or other debris may fly off objects when objects
cylinder or while you are using an ether spray. are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49° C
(120° F). Keep ether cylinders away from open
flames or sparks.
SEBU9068 13
Safety Section
Mounting and Dismounting
i05768982
Mounting and Dismounting
Do not climb on the engine or the engine

aftertreatment system. The engine and aftertreatment
system have not been designed with mounting or
dismounting locations.
Refer to the OEM for the location of foot and hand
holds for your specific application.
i05835985
High Pressure Fuel Lines

(1) High-pressure line (3) High-pressure line (5) High-pressure fuel manifold (rail)
(2) High-pressure line (4) High-pressure line (6) Fuel transfer line that is high pressure
14 SEBU9068
Safety Section
Before Starting Engine
The high-pressure fuel lines are the fuel lines that are • Inspect the high-pressure fuel lines for damage,
between the high-pressure fuel pump and the high- deformation, a nick, a cut, a crease, or a dent.
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These • Do not operate the engine with a fuel leak. If there
fuel lines are different from fuel lines on other fuel is a leak, do not tighten the connection in order to
systems. stop the leak. The connection must only be
tightened to the recommended torque. Refer to
These differences are because of the following items:
Disassembly and Assembly, “Fuel injection lines -
• The high-pressure fuel lines are constantly Remove and Fuel injection lines - Install”.
charged with high pressure.
• If the high-pressure fuel lines are torqued correctly,
• The internal pressures of the high-pressure fuel and the high-pressure fuel lines are leaking the
lines are higher than other types of fuel system. high-pressure fuel lines must be replaced.
• The high-pressure fuel lines are formed to shape • Ensure that all clips on the high-pressure fuel lines
and then strengthened by a special process. are in place. Do not operate the engine with clips
that are damaged, missing, or loose.
Do not step on the high-pressure fuel lines. Do not
deflect the high-pressure fuel lines. Do not bend or • Do not attach any other item to the high-pressure
strike the high-pressure fuel lines. Deformation or fuel lines.
damage of the high-pressure fuel lines may cause a
point of weakness and potential failure. • Loosened high-pressure fuel lines must be
replaced. Also removed high-pressure fuel lines
Do not check the high-pressure fuel lines with the must be replaced. Refer to Disassembly and
engine or the starting motor in operation. After the Assembly, “Fuel Injection Lines - Install”.
engine has stopped wait for 10 minutes in order to
allow the fuel pressure to be purged from the high-
pressure fuel lines before any service or repair is i03560601
performed.
Do not loosen the high-pressure fuel lines in order to
remove air from the fuel system. This procedure is not
required.
Visually inspect the high-pressure fuel lines before NOTICE
the engine is started. This inspection should be each For initial start-up of a new or rebuilt engine, and for
day. start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
If you inspect the engine in operation, always use the occur. This may be accomplished by shutting off the
proper inspection procedure in order to avoid a fluid air and/or fuel supply to the engine.
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
Engine exhaust contains products of combustion

which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
Inspect the engine for potential hazards.

Do not start the engine or move any of the controls if
there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or to
the controls.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
SEBU9068 15
Safety Section
Engine Starting
All protective guards and all protective covers must Note: The engine is equipped with a device for cold
be installed if the engine must be started in order to starting. If the engine will be operated in very cold
perform service procedures. To help prevent an conditions, then an extra cold starting aid may be
accident that is caused by parts in rotation, work required. Normally, the engine will be equipped with
around the parts carefully. the correct type of starting aid for your region of
operation.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are These engines are equipped with a glow plug starting
provided in order to help prevent personal injury. The aid in each individual cylinder that heats the intake air
circuits are also provided in order to help prevent in order to improve starting. Some Perkins engines
engine damage.
may have a cold starting system that is controlled by
See the Service Manual for repairs and for the ECM that allows a controlled flow of ether into the
engine. The ECM will disconnect the glow plugs
adjustments.
before the ether is introduced. This system would be
installed at the factory.
i03996487
Engine Starting i02234873
Engine Stopping
Stop the engine according to the procedure in the

Do not use aerosol types of starting aids such as Operation and Maintenance Manual, “Engine
ether. Such use could result in an explosion and Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
personal injury. the engine components.
If a warning tag is attached to the engine start switch, Use the Emergency Stop Button (if equipped) ONLY
or to the controls DO NOT start the engine or move in an emergency situation. Do not use the Emergency
the controls. Consult with the person that attached Stop Button for normal engine stopping. After an
the warning tag before the engine is started. emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
All protective guards and all protective covers must corrected.
be installed if the engine must be started in order to Stop the engine if an overspeed condition occurs
perform service procedures. To help prevent an during the initial start-up of a new engine or an engine
accident that is caused by parts in rotation, work that has been overhauled.
around the parts carefully.
To stop an electronically controlled engine, cut the
Start the engine from the operators compartment or power to the engine and/or shutting off the air supply
from the engine start switch. to the engine.
Always start the engine according to the procedure
that is described in the Operation and Maintenance i04112409
Manual, “Engine Starting” topic in the Operation
Section. Knowing that the correct procedure will help Electrical System
to prevent major damage to the engine components.
Knowing that the procedure will also help to prevent
personal injury.
Never disconnect any charging unit circuit or battery
To ensure that the jacket water heater (if equipped) circuit cable from the battery when the charging unit is
and/or the lube oil heater (if equipped) is working operating. A spark can cause the combustible gases
correctly, check the water temperature gauge. Also, that are produced by some batteries to ignite.
check the oil temperature gauge during the heater
operation. To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
Engine exhaust contains products of combustion negative “−” cable should be connected last from the
which can be harmful to your health. Always start the external power source to the negative “−” terminal of
engine and operate the engine in a well ventilated the starting motor. If the starting motor is not
area. If the engine is started in an enclosed area, vent equipped with a negative “−” terminal, connect the
the engine exhaust to the outside. cable to the engine block.
16 SEBU9068
Safety Section
Electrical System
Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical
connections before the engine is started. Repair all
frayed electrical wires before the engine is started.
See the Operation and Maintenance Manual for
specific starting instructions.
Grounding Practices
Typical example
(5) Ground to battery
(6) Ground to engine block
(7) Primary position for grounding
Correct grounding for the engine electrical system is

necessary for optimum engine performance and
reliability. Incorrect grounding will result in
Illustration 12 g02315896 uncontrolled electrical circuit paths and in unreliable
Typical example electrical circuit paths.
(1) Ground to battery
(2) Primary position for grounding Uncontrolled electrical circuit paths can result in
(3) Ground to engine block damage to engine components.
(4) Ground to starting motor
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
To ensure the engine and the engine electrical
systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine ground to the frame.
The connections for the grounds should be tight and
free of corrosion. The engine alternator must be
grounded to the negative “-” battery terminal with a
wire adequate to handle the full charging current of
the alternator.
The power supply connections and the ground
connections for the engine electronics should always
be from the isolator to the battery.
SEBU9068 17
Safety Section
Engine Electronics
i04346349 The Engine Monitoring package can vary for different

engine models and different engine applications.
Engine Electronics However, the monitoring system and the engine
monitoring control will be similar for all engines.
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.
Electrical Shock Hazard. The electronic unit injec-

tors use DC voltage. The ECM sends this voltage
to the electronic unit injectors. Do not come in
contact with the harness connector for the elec-
tronic unit injectors while the engine is operating.
Failure to follow this instruction could result in
personal injury or death.
This engine has a comprehensive, programmable

Engine Monitoring System. The Electronic Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine
monitoring control:
• Warning
• Derate
• Shutdown
The following monitored engine operating conditions
and components have the ability to limit engine speed
and/or the engine power :
• Engine Coolant Temperature

• Engine Oil Pressure
• Engine Speed
• Intake Manifold Air Temperature
• Engine Intake Throttle Valve Fault

• Wastegate Regulator
• Supply Voltage to Sensors

• Fuel Pressure in Manifold (Rail)
• NOxReduction System
• Engine Aftertreatment System
18 SEBU9068
Product Information Section
Model View Illustrations
Product Information
Section
General Information
i05837601
The following model views show typical features of

the engine. Due to individual applications, your
engine may appear different from the illustrations.
Engine with Rear Mounted Aftertreatment
Typical example
(1) Front lifting eye (6) Primary fuel filter (11) Spin-on oil filter
(2) Rear lifting eyes (7) Water in fuel switch (12) Oil gauge (Dipstick)
(3) Diesel exhaust fluid injector (8) Secondary fuel filter (13) Oil filler cap
(4) Rear mounted aftertreatment (9) Flywheel (14) High-pressure fuel pump
(5) Priming pump (10) Flywheel housing
SEBU9068 19
General Information
Typical example
(15) Electronic control module (17) Breather (19) Coolant pump
(16) Fan pulley (18) Crankshaft pulley (20) Air intake
20 SEBU9068
General Information
Typical example
(21) Turbocharger (25) Alternator (29) Starter solenoid
(22) Air outlet connection from turbocharger (26) Coolant intake connection (30) Flex pipe
(23) Air intake from air cleaner (27) Coolant drain
(24) Coolant outlet connection (28) Starting motor
SEBU9068 21
General Information
Product Description
Off Engine Components
Typical example
(1) Inlet air temperature sensor (6) Selective Catalytic Reduction (SCR) (11) Ammonia sensor and controller
(2) Breather heater (7) SCR Outlet manifold (12) Temperature sensors for Doc and SCR
(3) Heater line controller (8) Diesel Exhaust Fluid (DEF) tank (13) DEF pump module with DEF filter
(4) Glow plug control unit (9) DEF Heated line
(5) Coolant diverter valve (10) NOx Sensor
i05857921 Engine Specifications

Product Description Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.
The Perkins 854F-E34TA industrial engine have the
following characteristics
• In-line 4 cylinder
• Four valves per cylinder
• Four stroke cycle

• Turbocharged charge cooled
• Aftertreatment system
22 SEBU9068
General Information
Product Description
• Engine monitoring
• Engine speed governing
• Control of the injection pressure

• Cold start strategy
• Automatic air/fuel ratio control

• Torque rise shaping
• Injection timing control

• System diagnostics
• Aftertreatment Regeneration
Cylinder and valve location For more information on electronic engine features,
(A) Exhaust valves refer to the Operation and Maintenance Manual,
(B) Inlet valves “Features and Controls” topic (Operation Section).
Table 1 Engine Diagnostics
854F-E34TA Engine Specifications
The engine has built-in diagnostics in order to ensure
Operating Range (rpm) 800 to 2750(1) that the engine systems are functioning correctly. The
operator will be alerted to the condition by a “Stop or
Number of Cylinders 4 In-Line Warning” lamp. Under certain conditions, the engine
Bore 99 mm (3.89763 inch) horsepower and the vehicle speed may be limited.
The electronic service tool may be used to display the
Stroke 110 mm (4.33070 inch) diagnostic codes.
Power Turbocharged Charge Cooled There are three types of diagnostic codes: active,
63 to 90 kW logged and event.
(84.48 to 120.69 hp)
Most of the diagnostic codes are logged and stored in
Aspiration Turbocharged charge cooled
the ECM. For additional information, refer to the
Compression Ratio 17: 1
Operation and Maintenance Manual, “Engine
Diagnostics” topic (Operation Section).
Displacement 3.4 L (207.48 cubic inch)
The ECM provides an electronic governor that
Firing Order 1-3-4-2 controls the injector output in order to maintain the
desired engine rpm.
Rotation (flywheel end) Counterclockwise
(1) The operating rpm is dependent on the engine rating, the appli- Engine Cooling and Lubrication
cation, and the configuration of the throttle.
The cooling system and lubrication system consists
of the following components:
Electronic Engine Features
• Belt driven centrifugal water pump
The engine operating conditions are monitored. The
Electronic Control Module (ECM) controls the • Water temperature regulator which regulates the
response of the engine to these conditions and to the
engine coolant temperature
demands of the operator. These conditions and
operator demands determine the precise control of • Gear-driven rotor type oil pump
fuel injection by the ECM. The electronic engine
control system provides the following features: • Multi plate oil cooler
The engine lubricating oil is cooled and the engine
lubricating oil is filtered.
SEBU9068 23
General Information
Product Description
Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants, and
lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
Aftertreatment System
The aftertreatment system is approved for use by
Perkins . In order to be emission-compliant only the
approved Perkins aftertreatment system must be
used on a Perkins engine.
The aftertreatment system is Diesel Oxidation
Catalyst (DOC) and Selective Catalytic Reduction
(SCR), with Diesel Exhaust Fluid (DEF) injection.
The engine is connected by a flexible pipe to the
aftertreatment. The exhaust gases pass through the
DOC and then the mixer where the gases are mixed
with the injected urea. The mixture then enters the
SCR catalyst. Here the NOx in the exhaust reacts
with the ammonia from the injected urea to split the
gases into nitrogen and oxygen constituents. The
SCR catalyst includes an ammonia oxidation section
to clean up any remaining ammonia before the gases
exit the system.
Aftertreatment Configuration
The engine can be configured with a top mounted
aftertreatment or an aftertreatment mounted across
the rear of the engine.
Aftermarket Products and Perkins

Engines
Perkins does not warrant the quality or performance
of non-Perkins fluids and filters.
When auxiliary devices, accessories, or consumables
(filters, additives, catalysts,) which are made by other
manufacturers are used on Perkins products, the
Perkins warranty is not affected simply because of
such use.
However, failures that result from the installation
or use of other manufacturers devices,
accessories, or consumables are NOT Perkins
defects. Therefore, the defects are NOT covered
under the Perkins warranty.
24 SEBU9068
Product Identification Information
Plate Locations and Film Locations
Product Identification Serial Number location

Information
i05857940
Plate Locations and Film

Locations
(Aftertreatment)
S
Ensure that all numbers on the aftertreatment are

recorded
Your Perkins distributor or your dealer will require all
the numbers in order to identify the components for
your aftertreatment
i05857938
Plate Locations and Film

Locations Illustration 19 g03733236
Typical example of a non-stressed cylinder block
Perkins engines are identified by an engine serial The engine serial number can be installed in three
number. different positions.
An example of an engine number is All engines will have the serial number install in
JU*****L000001V. location (1) on the front face of the engine.
***** The list number for the engine On a non-stressed cylinder block the serial number is
located in position (2). On the left-hand side on the
JU The type of engine cylinder block.
L Built in the Italy
000001 Engine Serial Number
V Year of Manufacture
Perkins dealers or Perkins distributors need all of
these numbers in order to determine the components
that were included with the engine. This information
permits accurate identification of replacement part
numbers.
The numbers for fuel setting information for electronic
engines are stored within the flash file. These
numbers can be read by using the electronic service
tool.
Typical example
On a stressed cylinder block the serial number is

located in position (3).
SEBU9068 25
Product Identification Information
Emissions Certification Film
The engine serial number is stamped on the

emissions plate.
i05847996
Emissions Certification Film
The emission label will be installed on the left side of

the non-stressed cylinder block. The emission label
will be installed on the left side of the engine oil pan
for stressed cylinder blocks
Typical example
i05837789 Auxiliary Oil Filter Element
Reference Information Total Lubrication System Capacity

Total Cooling System Capacity
Information for the following items may be needed to Air Cleaner Element
order parts. Locate the information for your engine.
Record the information in the appropriate space. Drive Belt
Make a copy of this list for a record. Keep the
information for future reference. Aftertreatment System
Record for Reference Part Number
Engine Model Serial Number
Engine Serial number
Engine Low Idle rpm
Engine Full Load rpm
Primary Fuel Filter
Secondary Fuel Filter Element
Lubrication Oil Filter Element
26 SEBU9068
Operation Section
Product Lifting
Operation Section
Lifting and Storage

i05858019
Product Lifting
Typical example of lifting eyes with top mounted
aftertreatment
(1) Front lifting eye
(2) Rear lifting eyes
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
Use a hoist to remove heavy components. Use an

adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Typical example
Some removals require lifting the fixtures in order to
obtain correct balance and safety.
The lifting eyes should be used to lift only the engine
as supplied by Perkins , including engine mounted
aftertreatment equipment.
Other Original Equipment Manufacturer (OEM)
equipment, including transmissions, should be
removed from the engine prior to lifting. For more
information, refer to the OEM.
Lifting eyes are designed and installed for specific
engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure that
correct lifting devices are provided. Consult your
Perkins distributor for information regarding fixtures
for correct engine lifting.
SEBU9068 27
Lifting and Storage
Product Storage
Note: The engine is equipped with three lifting eyes. 2. Drain any water from the primary filter water
All the lifting eyes must be used in order to lift the separator. Ensure that the fuel tank is full.
engine and the aftertreatment.
3. The engine oil will not need to be drained in order
The aftertreatment system has not been designed to store the engine. Provided the correct
with lifting eyes for removal from the engine or
application. In order to remove aftertreatment, the specification of engine oil is used the engine can
aftertreatment must be lifted using two lifting slings. be stored for up to 6 months. For the correct
When installing the aftertreatment, use two lifting specification of engine oil refer to this Operation
slings in order to install the aftertreatment. and Maintenance Manual, “Fluid
recommendations”.
i05858063
4. Remove the drive belt from the engine.
Product Storage Sealed Coolant System
(Engine and Aftertreatment)
Ensure that the cooling system is filled with Perkins
ELC, or an antifreeze that meets “ASTM D6210”
Perkins are not responsible for damage which may specification.
occur when an engine is in storage after a period in
service. Open Cooling System
Your Perkins dealer or your Perkins distributor can Ensure that all cooling drain plugs have been
assist in preparing the engine for extended storage opened. Allow the coolant to drain. Install the drain
periods. plugs. Place a vapor phase inhibitor into the system.
The coolant system must be sealed once the vapor
Condition for Storage phase inhibitor has been introduced. The effect of the
vapor phase inhibitor will be lost if the cooling system
The engine must be stored in a water proof building. is open to the atmosphere.
The building must be kept at a constant temperature.
Engines that are filled with Perkins ELC will have For maintenance procedures ref to this Operation and
coolant protection to an ambient temperature of Maintenance Manual.
−36° C (−32.8° F). The engine must not be subjected
to extreme variations in temperature and humidity.
Monthly Checks
Storage Period The crankshaft must be rotated in order to change the
spring loading on the valve train. Rotate the
An engine can be stored for up to 6 months provided crankshaft more than 180 degrees. Visibly check for
all the recommendation are adhered to. damage or corrosion to the engine and
aftertreatment.
Storage Procedure Ensure that the engine and aftertreatment are
covered completely before storage. Log the
Keep a record of the procedure that has been procedure in the record for the engine.
completed on the engine.
Note: Do not store an engine that has biodiesel in the
Aftertreatment
fuel system. The engine must be allowed to perform a DEF purge
before the battery disconnect switch is turned off.
1. Ensure that the engine is clean and dry. Allow 2 minutes after the engine has stopped before
disconnecting the battery disconnect switch.
a. If the engine has been operated using
biodiesel, the system must be drained and The exhaust outlet of the aftertreatment must be
capped. In order to prevent damage to the exhaust
new filters installed. The fuel tank will require outlet connection during storage.
flushing.
b. Fill the fuel system with an ultra low sulfur fuel. DEF Tank Storage
For more information on acceptable fuels refer
to this Operation and Maintenance Manual, 1. Ensure normal engine shutdown, allow the DEF to
“Fluid recommendations”. Operate the engine be purged. Do not disconnect the battery
for 15 minutes in order to remove all biodiesel disconnect switch, allow 2 minutes after key off
from the system. before disconnection.
28 SEBU9068
Lifting and Storage
Product Storage
2. Fill the tank with DEF that meet all the requirement
defined in ISO 22241-1.
3. Ensure that all DEF lines and electrical connection
are connected prior to prevent crystal from
forming.
4. Ensure that the DEF filler cap is correctly installed.
Removal from Storage

DEF has a limited life, refer to table 2 for the time and
temperature range. DEF that is outside this range
MUST be replaced.
On removal from storage the DEF quality in the tank
must be tested with a refractometer. The DEF in the
tank must meet the requirements defined in ISO
22241-1 and comply with table 2 .
1. If necessary, drain the tank and fill with DEF that

meet ISO 22241-1.
2. Replace the DEF filter, refer to this Operation and
Maintenance Manual, “Diesel Exhaust Fluid Filter-
Clean/Replace”.
3. Ensure that the drive belt is correctly installed.

Ensure that all engine coolant and engine oil has
the correct specification and grade. Ensure that the
coolant and the engine oil are at the correct level.
Start the engine. If a fault becomes active turn off
the engine, allow 2 minutes for the DEF system to
purge, then restart the engine.
4. If the fault continues to stay active, refer to

Troubleshooting for more information.
Table 2
Temperature Duration
10° C (50° F) 36 months
25° C (77° F) 18 months
30° C (86° F) 12 months
35° C (95° F)(1) 6 months

(1) At 35° C, significant degradation can occur. Check every batch
before use.
SEBU9068 29
Features and Controls
Alarms and Shutoffs
Features and Controls Intake manifold pressure – The intake manifold

pressure sensor checks the rated pressure in the
engine manifold.
i05951738
Fuel rail pressure – The fuel rail pressure sensor
Alarms and Shutoffs measures the high pressure or low pressure in the
fuel rail. The ECM will Check the pressure.
Engine oil pressure – The engine oil pressure
sensor indicates when oil pressure drops below rated
Shutoffs system pressure, at a set engine speed.
The shutoffs are electrically operated or mechanically Engine overspeed – If, the engine rpm exceeds the
operated. The electrically operated shutoffs are overspeed setting the alarm will be activated.
controlled by the Electronic Control Module (ECM).
Air filter restriction – The switch checks the air filter
Shutoffs are set at critical levels for the following when the engine is operating.
items:
User-defined switch – This switch can shut down
• Operating temperature the engine remotely. There will be no alarm or
warning lamp to show that the switch has been
• Operating pressure operated.
Water in fuel switch – This switch checks for water
• Operating level in the primary fuel filter when the engine is operating.
• Operating rpm Fuel temperature – The fuel temperature sensor
monitors the pressurized fuel in the high-pressure fuel
• Hydrocarbon build-up pump.
The particular shutoff may need to be reset before the Coolant temperature – The coolant temperature
engine will start. sensor indicates high jacket water coolant
temperature.
NOTICE
Always determine the cause of the engine shutdown. Note: The sensing element of the coolant
Make necessary repairs before attempting to restart temperature sensor must be submerged in coolant in
the engine. order to operate.
Engines may be equipped with alarms in order to
Be familiar with the following items: alert the operator when undesirable operating
conditions occur.
• Types and locations of shutoff
• Conditions which cause each shutoff to function NOTICE

When an alarm is activated, corrective measures
• The resetting procedure that is required to restart must be taken before the situation becomes an emer-
the engine gency in order to avoid possible engine damage.
Alarms If corrective measures are not taken within a

The alarms are electrically operated. The operations reasonable time, engine damage could result. The
of the alarms are controlled by the ECM. alarm will continue until the condition is corrected.
The alarm may need to be reset.
The alarm is operated by a sensor or by a switch.
When the sensor or the switch is activated, a signal is Aftertreatment System
sent to the ECM. An event code is created by the
ECM. The ECM will send a signal in order to • Temperature Sensor before DOC
illuminate the lamp.
• Two NOx Sensors
Your engine may be equipped with the following
sensors or switches: • Two SCR Temperature Sensors
Intake manifold air temperature – The intake
manifold air temperature sensor indicates high intake • Ammonia Sensor
air temperature. Temperature Sensor before DOC – This sensor
monitors the gas temperature that is entering the
DOC
30 SEBU9068
Selective Catalytic Reduction Warning System
NOx Sensor – Two NOx sensors monitor the NOx i05858075

concentration within the exhaust gas. One sensor
before the DOC and one after the SCR module. Selective Catalytic Reduction
SCR Temperature Sensors – The sensor monitors
the gas temperature entering the SCR. Also, a
Warning System
second temperature sensor is located down stream of
the SCR. This sensor checks the temperature of the
gas that is leaving the SCR. The Selective Catalytic Reduction (SCR) system is a
system used to reduce NOx emissions from the
Ammonia Sensor – The sensor monitors the engine. Diesel Exhaust Fluid (DEF) is pumped from
concentration of ammonia within the exhaust system the DEF tank and is sprayed into the exhaust stream.
after the CEM. The DEF reacts with the SCR catalyst to reduce NOx
and leaves a nitrogen and water vapor.
Quality Sensor – The quality sensor provides the
ECM with confirmation that the correct concentration
of DEF is present in the tank. If the tank is filled with a NOTICE
different fluid which is not DEF, such as water or fuel Stopping the engine immediately after the engine has
the sensor will detect this change in quality and raise been working under load can result in overheating of
a fault. This fault will lead to an inducement and DEF system components.
engine derate.
Refer to the Operation and Maintenance Manual, “En-
gine Stopping” procedure to allow the engine to cool
The temperature sensor before DOC, NOx sensor, and to prevent excessive temperatures in the turbo-
SCR temperature sensors, and ammonia sensor all charger housing and the DEF injector.
connect with the engine ECM. If the signal from these
sensors is out of the set range, the ECM will trigger
an alarm for the operator.
NOTICE
Allow at least 2 minutes after the engine has stopped
Diesel Exhaust Fluid (DEF) System before you turn the battery disconnect switch to OFF.
Control Disconnecting the battery power too soon will prevent
purging of the DEF lines after the engine is shut
DEF Level Sensor – The DEF level sensor signals down.
the ECM. The ECM determines the signal in order to
give a level reading of the volume of fluid in the tank.
DEF Temperature Sensor – The sensor signals the Warning Strategy
ECM. The ECM will determine the temperature of the
DEF within the tank from the signals sent. The The engine ECM will have software enabled in order
temperature of the DEF is important in order to keep to warn, derate, and only operate a low idle. This
the DEF injector operation correctly. software is in order to keep the engine emissions
complaint.
Dosing Control Unit (DCU) – The DCU controls the
injection of the DEF and will signal the ECM if the Warning Indicators
injection has been interrupted.
The warning indicators consist of a level gauge for
the DEF, a low-level lamp for the DEF, an emission
The DEF level sensor, DEF temperature sensor, and malfunction lamp, a warning lamp, a DEF quality
the Dosing control unit all connect with the engine lamp, and the application stop lamp.
ECM. If the ECM determines that any of the signals
are out of the specified range, an alarm will be The DEF level gauge will only give an accurate
triggered. reading with the application on level ground.
Testing
Turning the keyswitch to the ON position will check
the indicator lights on the control panel. All the
indicator lights will be illuminated for 2 seconds after
the keyswitch is operated. Replace suspect bulbs
immediately.
Refer to Troubleshooting for more information.
SEBU9068 31
• Turn on key switch for a minimum 5 seconds to a

maximum of 15 seconds
• Turn off key switch for a minimum 5 seconds to a

maximum of 15 seconds
• Turn on key switch for a minimum 5 seconds to a
maximum of 15 seconds, then crank engine in
order to start.
Inducement for low-level DEF

When low-level DEF inducement is active there is no
override option to cycle the key switch.
Before engine operation, ensure that the DEF tank is
Illustration 24 g03069862 full. Also, ensure that there is an adequate supply of
(1) DEF Level gauge DEF in order to refill the DEF tank.
(A) Low-level warning lamp
Emission malfunction lamp
Warning Indicator Lamps

The warning indicator lamps can function in three
different modes.
• On solid
• Slow flash (once a second)
• Fast flash (twice a second)
Warning Levels
Any warning should be investigated immediately,
contact your Perkins dealer or your Perkins
distributor. The system is equipped with an override
option. Once the override option has been used and
the fault still exist, the engine will be locked in de-rate
at low idle only.
Override Option
The key switch can be cycled in order to give
emergency power for 30 minutes.
32 SEBU9068
Table 3
DEF in Tank Level
Warning Stop Indicator DEF Low Lev- Emission Mal- DEF in Tank Engine Power Time Comment Action
Indicator el Indicator function Level
Indicator
OFF OFF OFF OFF - Full Power - Normal None
Operation
OFF OFF On Solid OFF Less than 20 Full Power - Low DEF Indi- Stop Engine
Percent cator Active and Fill DEF
Tank
ON Solid OFF ON Solid ON Solid Less than Ten Full Power - Level 1 Indica-
Percent tors Active
ON Flashing OFF On Solid ON Flashing Less than Five Engine will Derate Timer A Level 2 In-
Slowly Slowly Percent Start to be Starts. ducement is
Derated Active
ON Flashing ON Solid ON Flashing ON Flashing Empty Tank Derate to en- Start of 30 Mi- A Level 3
Fast Fast Fast gine Power nute Timer nducement is
Active
ON Flashing ON Solid ON Flashing ON Flashing Engine will A Level 3 In-
Fast Fast Fast Only Operate ducement is
at Low Idle. Active
SEBU9068 33
Inducement for Poor DEF Quality

Table 4
Inducement for Poor DEF Quality
Warning Stop Indicator DEF Quality Emission Mal- Engine Power Time Comment Action
Indicator Indicator function
Indicator
OFF OFF OFF OFF Full Power - Normal None
Operation
On Solid OFF On Solid On Solid Full Power Start of 50 Mi- DEF Quality Out Stop Engine
nute Timer of Range Level and Check DEF
1 Inducement is Quality.
Active Refer to Sys-
tems Operation
ON Flashing OFF ON Solid ON Flashing Start of Engine Start of 40 Mi- A Level 2 In-
Testing and Ad-
Slowly Slowly Derate nute Derate ducement is
justing, “Diesel
Ramp Active
Exhaust fluid
ON Flashing ON Solid ON Solid ON Flashing Full Engine At 210 Minutes A Level 3 In- Quality - Test”
Fast Fast Derate. ducement is for More
Active Information.
Low Idle (RPM)
Only
34 SEBU9068
SCR System Inducements

Table 5
SCR System Inducements
Warning Indicator Stop Indicator Emission Malfunc- Engine Power Time Comment Action
tion Indicator
OFF OFF OFF Full Power - Normal Operation None
ON Solid or Slow OFF ON Solid Start of Engine Timer Starts, 240 A Level 1 Induce- Contact your Per-
Flashing (1) Power Derate Minutes Before Full ment is Active kins dealer or
Derate your Perkins
ON Flashing OFF ON Flashing Derate to Engine A Level 2 Induce- distributor.
Slowly Slowly Power and Speed ment is Active If a Code has been
Activated Provide
ON Flashing Fast ON Solid ON Flashing Fast Full Engine Derate A Level 3 Induce-
this Information to
ment is Active
Your Dealer.
Low Idle (RPM)
Only
(1) Lamp mode will depend on the issue that has been identified.
SEBU9068 35
Battery Disconnect Switch
NRS System Inducements

Table 6
NRS System Inducements
Warning Indicator Stop Indicator Emission Malfunc- Engine Power Time Comment Action
tion Indicator
OFF OFF OFF Full Power - Normal Operation None
ON Solid or Slow OFF ON Solid Start of Engine Timer Starts, 210 A Level 1 Induce- Contact your Per-
Flashing (1) Derate Minutes Before Full ment is Active kins dealer or
Derate your Perkins
ON Flashing OFF ON Flashing Derate to Engine A Level 2 Induce- distributor.
Slowly Slowly Power and Speed ment is Active If a Code has been
Activated Provide
this Information to
Your Dealer.
(1) Lamp mode will depend on the issue that has been identified.
i05837438 Noticeable changes in gauge readings indicate

potential gauge or engine problems. Problems may
Battery Disconnect Switch also be indicated by gauge readings that change
even if the readings are within specifications.
Determine and correct the cause of any significant
change in the readings. Consult your Perkins dealer
Allow at least 2 minutes after the engine has stopped for assistance.
before you turn the battery disconnect switch to OFF.
Disconnecting the battery power too soon will prevent In some engine applications are equipped with
purging of the Diesel Exhaust Fluid (DEF) lines after Indicator Lamps. Indicator lamps can be used as a
the engine is shut down. Also, during the 2 minutes diagnostic aid. There are two lamps. One lamp has
the engine Electronic Control Module (ECM) is active an orange lens and the other lamp has a red lens.
storing information from the engine and
aftertreatment sensors. These indicator lamps can be used in two ways:
Not allowing the DEF purge to be performed can • The indicator lamps can be used to identify the
damage the DEF system. Not allowing the engine current operational status of the engine. The
ECM time to store the information from the sensors indicator lamps can also indicate that the engine
can damage to emission control system. has a fault. This system is automatically operated
via the ignition switch.
NOTICE
Never move the battery disconnect switch to the OFF • The indicator lamps can be used to identify active
position while the engine is operating. Serious dam- diagnostic codes.
age to the electrical system could result.
Refer to the Troubleshooting Guide, “Indicator
Lamps” for further information.
i05858112
NOTICE
If no oil pressure is indicated, STOP the engine. If
Gauges and Indicators maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result.
Your engine may not have the same gauges or all of
the gauges that are described. For more information Engine Oil Pressure – The oil pressure
about the gauge package, see the OEM information. should be greatest after a cold engine is
started. The typical engine oil pressure
Gauges provide indications of engine performance. with SAE10W40 is 400 to 480 kPa (58 to 69 psi) at
Ensure that the gauges are in good working order.
Determine the normal operating range by observing rated rpm.
the gauges over a period of time. A lower oil pressure is normal at low idle. If the engine
speed and Load are stable and the gauge reading
changes, perform the following procedure:
1. Remove the load.
36 SEBU9068
Gauges and Indicators
Low Level DEF – The gauge indicates

2. Stop the engine. the amount of DEF in the tank. Level
ground is required for correct operation
3. Check and maintain the oil level. of the gauge.
Jacket Water Coolant Temperature – Indicator Lamps

Typical temperature range is 82° to 94°C
(179.6° to 201.2°F). This temperature There are four indicator lamps that are available.
range will vary according to engine load and the
ambient temperature. • Shutdown Lamp
A 100 kPa (14.5 psi) radiator cap must be installed • Warning Lamp
on the cooling system. The maximum temperature for
the cooling system is 108° C (226.4° F). This • Wait to Start Lamp
temperature is measured at the outlet for the water
temperature regulator. The engine coolant • Low Oil Pressure Lamp
temperature is regulated by the engine sensors and
the engine ECM. This programming cannot be For information, refer to this manual, “Monitoring
altered. An engine derate can occur if the maximum System (Table for the Indicator Lamps)” for the
engine coolant temperature is exceeded. sequence of operation of the shutdown lamp and the
warning lamp.
If the engine is operating above the normal range,
reduce the engine load. If high coolant temperatures The function of the wait to start lamp is automatically
are a frequent event, perform the following controlled at engine start-up.
procedures:
The function of the low oil pressure lamp is controlled
by the engine ECM. If low oil pressure is detected, the
1. Reduce the load and the engine rpm. lamp will be illuminated. The reason for the
illumination of the low-pressure lamp should be
2. Determine if the engine must be shut down investigated immediately.
immediately or if the engine can be cooled by
reducing the load. All lamps will illuminate for 2 seconds in order to
check that the lamps are functioning when the
3. Inspect the cooling system for leaks. If necessary, keyswitch is turned to the ON position. If any of the
consult your Perkins dealer for assistance. lamps stay illuminated, the reason for illumination
should be investigated immediately.
Tachometer – This gauge indicates
engine speed (rpm). When the throttle Instrument panels and Displays
control lever is moved to the full throttle
position without load, the engine is running at In order to monitor the engine a wide verity of
high idle. The engine is running at the full load instrument panels are available. These instrument
panels can contain the indicator lamps and the
rpm when the throttle control lever is at the full gauges for the application.
throttle position with maximum rated load.
Also available are mini power displays and
NOTICE performance monitors. These displays and monitors
Operation at speeds exceeding high idle rpm should can show the operator the following engine
be kept to a minimum. Overspeeding can result in information.
serious damage to the engine.
Ammeter – This gauge indicates the

amount of charge or discharge in the
battery charging circuit. Operation of the
indicator should be to the “ +”” side of “ 0”” (zero).
Fuel Level – This gauge indicates the

fuel level in the fuel tank. The fuel level
gauge operates when the “ START/
STOP”” switch is in the “ on”” position.
Service Hour Meter – The gauge
indicates total operating hours of the
engine.
SEBU9068 37
Monitoring System
• The system configuration parameters

• The customer specified parameters
• Diagnostic codes
• Event codes
• Coolant temperature
• Oil temperature
• Oil pressure
• Intake temperature
• Intake pressure
• Atmospheric pressure
• Fuel temperature
Aftertreatment Lamps and Gauges

• Emission malfunction lamp
• Action indicator lamp

• Gauge for Diesel Exhaust Fluid (DEF)
• Low warning lamp for DEF
i04710837
Monitoring System
(Table for the Indicator lamps)
When in operation the amber warning indicator has

three states, on solid, flashing and fast flashing. The
sequence is to give a visual indication of the
importance of the warning. Some application can
have an audible warning installed.
38 SEBU9068
Monitoring System
Table 7
Warning Shutdown Lamp State Description of the Indication Engine Status Operator Action
Indicator Indicator
On On Indicator Check When the keyswitch is moved to the The keyswitch is in the ON If any of the indicators
ON position, the lamps will illumi- position but the engine has will not illuminate during
nate for 2 seconds and the lamps not yet been cranked. indicator check, the fault
will then go off. must be investigated
immediately.
During indicator check, the after-
treatment indicators will also be If any Indicators stay il-
checked. luminated or flash, the
fault must be investi-
gated immediately.
Off Off No Faults With the engine in operation, there The engine is operating with None
are no active warnings, diagnostic no detected faults.
codes, or event codes.
Level 1
On Solid Off Warning Level 1 warning The engine is operating nor- As soon as possible the
mally but there is one or more fault should be
faults with the electronic man- investigated.
agement system for the
engine.
Level 2
Flashing Off Warning Level 2 warning The engine continues to be Stop the engine.
operated, but there are active Investigate the code.
diagnostic, or event codes
active.
Derate to engine power may
be applied.
Level 3
Flashing On solid Warning Level 3 warning The engine continues to be Stop the engine
If both the warning lamp and the operated, but the level of im- immediately.
shutdown lamp are in operation, portance of the warning has Investigate the fault
this issue indicates one of the fol- increased.
lowing conditions. The engine will automatically
shut down.
1. One or more of the shutdown val- If shut down is not enabled,
ues for the engine protection strat- the engine could be damaged
egy has been exceeded. if continued to be operated.
2. A serious active diagnostic code

has been detected.
3. After a short time period, the en-

gine may shut down.
SEBU9068 39
Monitoring System
i05858123 “ Warning””
Monitoring System The orange “Warning” lamp will turn “ON” and the
warning signal is activated continuously in order to
alert the operator that one or more of the engine
parameters is not within normal operating range.
“ Derate””
If the Shutdown mode has been selected and the
warning indicator activates, engine shutdown The orange “Warning” lamp will “flashing” . After the
may take as little as 20 seconds from the time the warning, the engine power will be derated.
warning indicator is activated. Depending on the The engine will be derated if the engine exceeds
application, special precautions should be taken preset operational limits. The engine derate is
to avoid personal injury. The engine can be re- achieved by restricting the amount of fuel that is
started following shutdown for emergency ma- available for each injection. The amount of this
neuvers, if necessary. reduction of fuel is dependent on the severity of the
fault that has caused the engine derate, typically up
to a limit of 50%. This reduction in fuel results in a
NOTICE predetermined reduction in engine power.
The Engine Monitoring System is not a guarantee
against catastrophic failures. Programmed delays “ Shutdown””
and derate schedules are designed to minimize false
alarms and provide time for the operator to stop the The orange warning will turn “ON” and the red
engine. shutdown lamp will also turn “ON” . After the warning,
the engine power will be derated. The engine will
continue at the rpm of the set derate until a shutdown
The following parameters are monitored: of the engine occurs. The engine can be restarted
after a shutdown for use in an emergency.
• Coolant temperature
A shutdown of the engine may occur in as little as 20
• Intake manifold air temperature seconds. The engine can be restarted after a
shutdown for use in an emergency. However, the
• Intake manifold air pressure cause of the initial shutdown may still exist. The
engine may shut down again in as little as 20
• Oil pressure seconds.
• Pressure in the fuel rail If there is a signal for high coolant temperature, there
will be a 2 second delay in order to verify the
• Engine speed/timing condition.
• Fuel temperature If there is a signal for low oil pressure, there will be a
2 second delay in order to verify the condition.
• Atmospheric pressure (Barometric pressure)
For information on the operation of the warning lamps
• Water in fuel switch and the shutdown lamp, refer to this Operation and
Maintenance Manual, “Monitoring System (Table for
• Inlet temperature of the diesel oxidation catalyst Indicator Lamps)”. For each of the programmed
modes, refer to Troubleshooting Guide, “Indicator
Lamps” for more information on Indicator Lamps.
Programmable Options and
Systems Operation For more information or assistance for repairs,
consult your Perkins dealer.
i04348489
If the Warning/Derate/Shutdown mode has been Overspeed

selected and the warning indicator activates,
bring the engine to a stop whenever possible. De-
pending on the application, special precautions
should be taken to avoid personal injury. • ECM Electronic Control Module
• RPM Revolutions Per Minute

The engine can be programmed to the following
modes:
40 SEBU9068
Overspeed
An overspeed is detected by the speed/timing

sensors.
The default overspeed is set at 2800. The ECM will
cut the power to the electronic unit injectors, until the
rpm drops below the overspeed setting. A diagnostic
fault code will be logged into the ECM memory and a
warning lamp will indicate a diagnostic fault code.
Some application may have a display panel in order
to alert the operator.
SEBU9068 41
Sensors and Electrical Components
i05847998

Engine Views
Typical example
(1) High-pressure fuel pump inlet metering (4) 62-pin engine interface connector (8) Water In Fuel (WIF) sensor
valve (5) Fuel temperature sensor (9) Primary speed/timing sensor (crankshaft)
(2) 10-pin engine interface connector (6) Fuel rail pressure sensor
(3) Intake throttle valve (7) Oil pressure switch
42 SEBU9068
Typical example
(10) NOx Reduction System (NRS) valve (13) Exhaust gas pressure sensor (16) Secondary speed/timing sensor
(11) Intake manifold air pressure and (14) Coolant temperature sensor (camshaft)
temperature sensor (15) Wastegate regulator (17) Electronic control module
(12) Exhaust temperature sensor connector
SEBU9068 43
On Engine Aftertreatment
Typical example
(18) Engine out NOx sensor (19) Diesel Exhaust Fluid (DEF) injector (20) DOC inlet temperature sensor
44 SEBU9068
Off Engine Electrical Components
Typical example
(21) Inlet air temperature sensor (25) Coolant diverter valve (29) Ammonia sensor
(22) Breather heater (26) DEF tank header unit (30) Control unit for the ammonia sensor
(23) Heater Control Unit (HCU) (27) Heated DEF line (31) SCR inlet/outlet temperature sensors
(24) Glow plug Control Unit (GCU) (28) Tailpipe out NOx sensor (32) DEF pump module
SEBU9068 45
Engine Diagnostics
Self-Diagnostics
Engine Diagnostics i04348749
i02651093
Fault Logging
Self-Diagnostics The system provides the capability of Fault Logging.
When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be
Perkins electronic engines have the capability to logged in the memory of the ECM. The codes that
perform a self-diagnostics test. When the system have been logged by the ECM can be identified by
detects an active problem, a diagnostic lamp is the electronic service tool. The active codes that have
activated. Diagnostic codes will be stored in been logged will be cleared when the fault has been
permanent memory in the Electronic Control Module rectified or the fault is no longer active.
(ECM). The diagnostic codes can be retrieved by
using the electronic service tool. Refer to i03554534
Troubleshooting, “Electronic Service Tools” for further
information.
Engine Operation with Active
Some installations have electronic displays that
provide direct readouts of the engine diagnostic Diagnostic Codes
codes. Refer to the manual that is provided by the
OEM for more information on retrieving engine
diagnostic codes. Alternatively refer to If a diagnostic lamp illuminates during normal engine
Troubleshooting, “Indicator Lamps” for further operation, the system has identified a situation that is
information. not within the specification. Use electronic service
tools to check the active diagnostic codes.
Active codes represent problems that currently exist.
These problems should be investigated first. Note: If the customer has selected “DERATE” and if
there is a low oil pressure condition, the Electronic
Logged codes represent the following items:
Control Module (ECM) will limit the engine power until
• Intermittent problems the problem is corrected. If the oil pressure is within
the normal range, the engine may be operated at the
• Recorded events rated speed and load. However, maintenance should
be performed as soon as possible.
• Performance history
The active diagnostic code should be investigated.
The problems may have been repaired since the The cause of the problem should be corrected as
logging of the code. These codes do not indicate that soon as possible. If the cause of the active diagnostic
a repair is needed. The codes are guides or signals code is repaired and there is only one active
when a situation exists. Codes may be helpful to diagnostic code, the diagnostic lamp will turn off.
troubleshoot problems.
Operation of the engine and performance of the
When the problems have been corrected, the engine can be limited as a result of the active
corresponding logged fault codes should be cleared. diagnostic code that is generated. Acceleration rates
may be significantly slower. Refer to the
Troubleshooting Guide for more information on the
i02651107
relationship between these active diagnostic codes
and engine performance.
Diagnostic Lamp
i01902995
A diagnostic lamp is used to indicate the existence of Engine Operation with

an active fault. Refer to Troubleshooting, “Indicator
Lamps” for more information. A fault diagnostic code Intermittent Diagnostic Codes
will remain active until the problem is repaired. The
diagnostic code may be retrieved by using the
electronic service tool. Refer to Troubleshooting,
“Electronic Service Tools” for more information. If a diagnostic lamp illuminates during normal engine
operation and the diagnostic lamp shuts off, an
intermittent fault may have occurred. If a fault has
occurred, the fault will be logged into the memory of
the Electronic Control Module (ECM).
46 SEBU9068
Engine Diagnostics
Configuration Parameters
In most cases, it is not necessary to stop the engine

because of an intermittent code. However, the
operator should retrieve the logged fault codes and
the operator should reference the appropriate
information in order to identify the nature of the event.
The operator should log any observation that could
have caused the lamp to light.
• Low power
• Limits of the engine speed

• Excessive smoke, etc
This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this
engine.
i05844821
The engine electronic control module (ECM) has two

types of configuration parameters. The system
configuration parameters and the customer specified
parameters.
The electronic service tool is required in order to alter
the configuration parameters.
System Configuration Parameters

System configuration parameters affect the emissions
of the engine or the power of the engine. System
configuration parameters are programmed at the
factory. Normally, system configuration parameters
would never require changing through the life of the
engine. System configuration parameters must be
reprogrammed if an ECM is replaced.
Customer Specified Parameters

Customer specified parameters allow the engine to
be configured to the exact needs of the application.
The electronic service tool is required in order to alter
the customer configuration parameters.
Customer parameters may be changed repeatedly as
operational requirements change.
Table 8
Customer Specified Parameters
Specified Parameters Record
Low Idle Speed
Throttle Position 1 Engine Speed
(continued)
SEBU9068 47
Engine Diagnostics
(Table 8, contd)
Engine Idle Shutdown Enable Status
Engine Idle Shutdown Delay Status
Throttle Lock Feature Installation Status

Multi State Input Switch Enable Status
Multi State Input Switch Control Purpose
Multi Position Throttle Switch Initialization Enable Status

Throttle Lock Engine Set Speed #1
Throttle Lock Increment Speed Ramp Rate
Throttle Lock Decrement Speed Ramp Rate
Throttle Lock Engine Set Speed Increment
Monitoring Mode Shutdowns
Limp Home Desired Engine Speed
Engine Acceleration Rate
Engine Location
High Exhaust System Temperature Indicator Installation Status
Oil Pressure Lamp Installation Status
Wait to Start Lamp Installation Status
Warning Lamp Installation Status
Shutdown Lamp Installation Status
Starter Relay Installation Status
Low Pressure Fuel Pump Installation Status
Remote Torque Speed Control Enable Status
Throttle Arbitration Method

Manual Throttle Arbitration Precondition Check
Throttle Enable Status
Throttle #1 Initial Lower Position
Throttle #1 Initial Upper Position
Throttle #1Idle Validation Switch Enable Status

Throttle #1Idle Validation Minimum Off Threshold
Throttle #1 Idle Validation Maximum On Threshold
Throttle #1 Lower Diagnostic Limit
Throttle #1 Upper Diagnostic Limit
Throttle #2 Initial Lower Position

Throttle #2 Initial Upper Position
(continued)
48 SEBU9068
Engine Diagnostics
(Table 8, contd)
Throttle #2 Idle Validation Switch Enable Status
Throttle #2 Idle Validation Minimum Off Threshold
Throttle #2 Idle Validation Maximum On Threshold
Throttle #2 Lower Diagnostic Limit
Throttle #2 Upper Diagnostic Limit
Engine Operation Mode #1 High Idle Speed
Engine Operation Mode #1 High Idle Droop Percentage
Engine Operation Mode #1 Throttle #1 Droop Percentage
Engine Operation Mode #1 TSC1 Droop Percentage
SEBU9068 49
Engine Starting
Engine Starting i05365825
Cold Weather Starting

i05844893
Perform the required daily maintenance and other Do not use aerosol types of starting aids such as
periodic maintenance before the engine is started. ether. Such use could result in an explosion and
Inspect the engine compartment. This inspection can personal injury.
help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, “Maintenance
Interval Schedule” for more information. The ability to start the engine will be improved at
temperatures below −18 °C (0 °F) from the use of a
• Ensure that the engine has an adequate fuel jacket water heater or extra battery capacity.
supply.
When Group 2 diesel fuel is used, the following items
• Open the fuel supply valve (if equipped). provide a means of minimizing starting problems and
fuel problems in cold weather: Engine oil pan heaters,
• Ensure that the engine has an adequate diesel jacket water heaters, fuel heaters and fuel line
exhaust fluid supply. insulation.
Use the procedure that follows for cold weather
NOTICE starting.
All valves in the fuel return line must be open and fuel
supply lines must be open. Damage to the fuel sys- Note: Do not adjust the engine speed control during
tem can occur if fuel lines are closed with the engine start-up. The electronic control module (ECM) will
in operation. control the engine speed during start-up.
1. Disengage any driven equipment.

If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air may
have entered the filter housing. Also, when fuel filters Note: During key ON, the indicator lamps will be
have been changed, some air pockets will be trapped illuminated for 2 seconds in order to check the lamp
in the engine. In these instances, prime the fuel operation. If any of the indicator lamps do not
system. Refer to the Operation and Maintenance illuminate check the bulb. If any indicator lamps stay
Manual, “Fuel System - Prime” for more information
on priming the fuel system. Also, check that the fuel illuminated or flash, refer to Troubleshooting,
specification is correct and that the fuel condition is “Indicator Lamp Circuit - Test”.
correct. Refer to the Operation and Maintenance 2. Turn the keyswitch to the RUN position. Leave the
Manual, “Fuel Recommendations”. keyswitch in the RUN position until the warning
light for the glow plugs is extinguished.
3. When the warning light for the glow plugs is

Engine exhaust contains products of combustion extinguished, turn the keyswitch to the START
which may be harmful to your health. Always start position in order to engage the electric starting
and operate the engine in a well ventilated area motor and crank the engine.
and, if in an enclosed area, vent the exhaust to the
outside. Note: The operating period of the warning light for the
glow plugs will change due to the ambient air
• Do not start the engine or move any of the controls temperature.
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or NOTICE
to the controls. Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
• Reset all of the shutoffs or alarm components.
If the engine fails to start within 30 seconds, release
• Ensure that any driven equipment has been the starter switch or button and wait two minutes to al-
disengaged. Minimize electrical loads or remove low the starting motor to cool before attempting to
start the engine again.
any electrical loads.
50 SEBU9068
Engine Starting
Starting the Engine
4. Allow the keyswitch to return to the RUN position Note: During the key on, the indicator lamps will be
after the engine starts. illuminated for 2 seconds in order to check lamp
operation. If any of the lamps do not illuminate, check
5. Repeat step 2 through step 4 if the engine fails to the bulb. If the fault remains refer to Troubleshooting,
start. “Indicator Lamp Circuit - Test”.
4. When the warning light for the glow plugs is
Note: After starting, the engine will be held at low extinguished, turn the keyswitch to the START
speed. The time held at low speed will depend on position in order to engage the electric starting
ambient temperature and time since last run. The motor and crank the engine.
procedure is in order to allow the engine systems to
stabilize. The engine should not be “raced” in order to Note: The operating period of the warning light for the
speed up the warm-up process. glow plugs will change due to the temperature of the
6. Allow the engine to idle for 3 to 5 minutes, or allow engine.
the engine to idle until the water temperature
indicator begins to rise. When idling after the NOTICE
engine has started in cold weather, increase the Do not engage the starting motor when flywheel is
engine rpm from 1000 to 1200 rpm. This operation turning. Do not start the engine under load.
will warm up the engine more quickly. Maintaining
an elevated low idle speed for extended periods If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to al-
will be easier with the installation of a hand throttle. low the starting motor to cool before attempting to
Allow the white smoke to disperse before start the engine again.
proceeding with normal operation.
7. Operate the engine at low load until all systems 5. Allow the keyswitch to return to the RUN position
reach operating temperature. Check the gauges after the engine starts. Ensure that all warning
during the warm-up period. lamps are off.
6. Repeat step 2 through step 5 if the engine fails to

i05365826
start.
Starting the Engine 7. After starting, the engine will be held at low speed.
The time held at low speed will depend on ambient
temperature and time since last run. The
Note: Do not adjust the engine speed control during procedure is in order to allow the engine systems
start-up. The electronic control module (ECM) will to stabilize.
control the engine speed during start-up.
8. If the engine will not start, refer to Troubleshooting,
Starting the Engine “Engine Cranks but Does Not Start”
1. Disengage any equipment that is driven by the i03663103

engine.
Starting with Jump Start
2. Turn the keyswitch to the first position power on.
Check that the low oil pressure lamp is on solid. If Cables
the lamp is on solid, the engine start sequence can
continue. If the lamp is flashing, and engine oil
change is required. Refer to this Operation and
Maintenance Manual, “Engine Oil and Filter -
Change” for more information. Improper jump start cable connections can cause
an explosion resulting in personal injury.
3. Turn the keyswitch to the RUN position. Leave the
keyswitch in the RUN position until the warning Prevent sparks near the batteries. Sparks could
light for the glow plugs is extinguished. cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
SEBU9068 51
Engine Starting
After Starting Engine
Note: If it is possible, first diagnose the reason for the After jump starting, the alternator may not be able to
starting failure. Refer to Troubleshooting, “Engine Will fully recharge batteries that are severely discharged.
Not Crank and Engine Cranks But Will Not Start” for The batteries must be replaced or charged to the
further information. Make any necessary repairs. If proper voltage with a battery charger after the engine
the engine will not start only due to the condition of is stopped. Many batteries which are considered
the battery, either charge the battery, or start the unusable are still rechargeable. Refer to Operation
engine by using another battery with jump start and Maintenance Manual, “Battery - Replace” and
Testing and Adjusting Manual, “Battery - Test”.
cables.
The condition of the battery can be rechecked after
the engine has been switched OFF. i05397433
NOTICE After Starting Engine

Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage After starting, the engine will be held at low speed.
the electrical system. The time held at low speed will depend on ambient
temperature and time since last run. The procedure is
Do not reverse the battery cables. The alternator can in order to allow the engine systems to stabilize.
be damaged. Attach ground cable last and remove
first. Note: In ambient temperatures from 0 to 60°C
(32 to 140°F), the warm-up time is approximately 3
Turn all electrical accessories OFF before attaching
the jump start cables. minutes. In temperatures below 0°C (32°F),
additional warm-up time may be required.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en- When the engine idles during warm-up, observe the
gine being started. following conditions:
Do not check the high-pressure fuel lines with the
1. Turn the start switch on the stalled engine to the engine or the starting motor in operation. If you
inspect the engine in operation, always use the
OFF position. Turn off all the engine's accessories.
proper inspection procedure in order to avoid a fluid
2. Connect one positive end of the jump start cable to Maintenance Manual, “General hazard Information”.
the positive cable terminal of the discharged
battery. Connect the other positive end of the jump • Check for any fluid or for any air leaks at idle rpm
start cable to the positive cable terminal of the and at one-half full rpm (no load on the engine)
electrical source. before operating the engine under load.
3. Connect one negative end of the jump start cable • Allow the engine to idle for 3 to 5 minutes, or allow
to the negative cable terminal of the electrical the engine to idle until the water temperature
source. Connect the other negative end of the indicator begins to rise. Check all gauges during
jump start cable to the engine block or to the the warm-up period.
chassis ground. This procedure helps to prevent Note: Gauge readings should be observed and the
potential sparks from igniting the combustible data should be recorded frequently while the engine
gases that are produced by some batteries. is operating. Comparing the data over time will help to
determine normal readings for each gauge.
Note: The engine ECM must be powered before the Comparing data over time will also help detect
starting motor is operated or damage can occur. abnormal operating developments. Significant
changes in the readings should be investigated.
4. Start the engine in the normal operating procedure.
Refer to this Operation and Maintenance Manual,
“Starting the Engine”.
5. Immediately after the engine is started, disconnect

the jump start cables in reverse order.
52 SEBU9068
Engine Operation
Engine Operation
Engine Operation Aftertreatment

The exhaust gases pass through the DOC and then
i05949882 the mixer where the gases are mixed with the injected
urea. The mixture then enters the SCR catalyst. Here
Engine Operation the NOx in the exhaust reacts with the ammonia from
the injected urea to split the gases into nitrogen and
oxygen constituents. The SCR catalyst includes an
ammonia oxidation section to clean up any remaining
• ECM Electronic Control Module ammonia before the gases exit the system.
• DOC Diesel Oxidation Catalyst For the aftertreatment system to operate correctly the
operator must ensure an adequate diesel exhaust
• SCR Selective Catalytic Reduction fluid supply. The aftertreatment system must operate
correctly in order for the engine to be emissions-
• RPM Revolutions Per Minute compliant.
• NOx Nitrogen Oxide Elevated Idle for Aftertreatment

Proper operation and maintenance are key factors in In some applications the engine low idle RPM will
obtaining the maximum life and economy of the automatically increase in order to lower the rate of
engine. If the directions in the Operation and hydrocarbon build-up within the SCR. The elevated
Maintenance Manual are followed, costs can be idle is controlled by the engine ECM. The software
minimized and engine service life can be maximized. within the ECM will calculate the build-up of
hydrocarbon and will increase idle RPM.
The time that is needed for the engine to reach
normal operating temperature can be less than the The hydrocarbon build-up occurs when the engine is
time taken for a walk-around inspection of the engine. left to idle for a long period. Operating the engine in
normal load conditions will remove the hydrocarbon
The engine can be operated at the rated rpm after the from the SCR.
engine is started and after the engine reaches
operating temperature. The engine will reach normal Constant speed engines and engines with an idle
operating temperature sooner during a low engine speed at or above 1100 RPM will not require the
speed (rpm) and during a low-power demand. This increase in the idle speed.
procedure is more effective than idling the engine at
no load. The engine should reach operating In some application the ECM software may be
temperature in a few minutes. configured in order to protect the aftertreatment
system from high hydrocarbons build up. This
Gauge readings should be observed and the data protection will shut down the engine.
should be recorded frequently while the engine is
operating. Comparing the data over time will help to
determine normal readings for each gauge. i01646335
Comparing data over time will also help detect
abnormal operating developments. Significant Engaging the Driven
changes in the readings should be investigated.
Equipment
In some application the ECM software may be
configured in order to stop an engine from extended
idling.
1. Operate the engine at one-half of the rated rpm,
System check when possible.
During normal engine operation the ECM will elevate 2. Engage the driven equipment without a load on the
the fuel pressure to the injectors. This check will be at equipment, when possible.
scheduled intervals of approximately 100 hours
depending on the duty cycle of the engine. The check Interrupted starts put excessive stress on the drive
will be carried out automatically without the need of train. Interrupted starts also waste fuel. To get the
any input from the operator. driven equipment in motion, engage the clutch
smoothly with no load on the equipment. This
During the time of elevated fuel pressure, the method should produce a start that is smooth and
operator may notice a change in the tone of the easy. The engine rpm should not increase and the
engine. The ECM will operate the check at low idle for clutch should not slip.
approximately 5 minutes.
3. Ensure that the ranges of the gauges are normal
when the engine is operating at one-half of the
rated rpm. Ensure that all gauges operate properly.
SEBU9068 53
Engine Operation
Fuel Conservation Practices
• The belt should be in good condition. Refer to the

4. Increase the engine rpm to the rated rpm. Always Systems Operation, Testing and Adjusting, “V-Belt
increase the engine rpm to the rated rpm before Test” for further information.
the load is applied.
• Ensure that all of the connections of the hoses are
5. Apply the load. Begin operating the engine at low tight. The connections should not leak.
load. Check the gauges and equipment for proper • Ensure that the driven equipment is in good
operation. After normal oil pressure is reached and working order.
the temperature gauge begins to move, the engine
may be operated at full load. Check the gauges • Cold engines consume excess fuel. Utilize heat
and equipment frequently when the engine is from the jacket water system and the exhaust
operated under load. system, when possible. Keep cooling system
components clean and keep cooling system
Extended operation at low idle or at reduced load components in good repair. Never operate the
may cause increased oil consumption and carbon engine without water temperature regulators. All of
buildup in the cylinders. This carbon buildup these items will help maintain operating
results in a loss of power and/or poor performance. temperatures.
i04018232
Fuel Conservation Practices
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 in
order to attain optimum performance for the life of the
engine.
• Avoid spilling fuel.
Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
• Be aware of the properties of the different fuels.

Use only the recommended fuels. Refer to the
Operations and Maintenance Manual, “Fuel
Recommendations”for further information.
• Avoid unnecessary idling.

Shut off the engine rather than idle for long periods of
time.
• Observe the service indicator frequently. Keep the

air cleaner elements clean.
• Ensure that the turbocharger is operating correctly.
For more information refer to this Operation and
Maintenance Manual, “Turbocharger - Inspect”
• Maintain a good electrical system.
One faulty battery cell will overwork the alternator.
This fault will consume excess power and excess
fuel.
54 SEBU9068
Cold Weather Operation
Cold Weather Operation Hints for Cold Weather Operation

• If the engine will start, operate the engine until a
i06024580 minimum operating temperature of 80° C (176° F)
is achieved. Achieving operating temperature will
Cold Weather Operation help prevent the intake valves and exhaust valves
from sticking.
• The cooling system and the lubrication system for

Perkins Diesel Engines can operate effectively in cold
weather. During cold weather, the starting and the the engine do not lose heat immediately upon
operation of the diesel engine is dependent on the shutdown. This means that an engine can be shut
following items: down for a period and the engine can still have the
ability to start readily.
• The type of fuel that is used
• Install the correct specification of engine lubricant
• The viscosity of the engine oil before the beginning of cold weather.
• The operation of the glow plugs • Check all rubber parts (hoses, fan drive belts,)
weekly.
• Optional Cold starting aid
• Check all electrical wiring and connections for any
• Battery condition fraying or damaged insulation.
This section will cover the following information: • Keep all batteries fully charged and warm.
• Potential problems that are caused by cold- • Fill the fuel tank at the end of each shift.
weather operation
• Check the air cleaners and the air intake daily.
• Suggest steps which can be taken in order to Check the air intake more often when you operate
minimize starting problems and operating in snow.
problems when the ambient air temperature is
between 0° to−40 °C (32° to 40 °F). • Ensure that the glow plugs are in working order.
Refer to Troubleshooting, “Glow Plug Starting Aid-
The operation and maintenance of an engine in Test”.
freezing temperatures is complex . This complexity is
because of the following conditions:
• Weather conditions
Personal injury or property damage can result
• Engine applications from alcohol or starting fluids.
Recommendations from your Perkins dealer or your Alcohol or starting fluids are highly flammable
Perkins distributor are based on past proven and toxic and if improperly stored could result in
practices. The information that is contained in this injury or property damage.
section provides guidelines for cold-weather
operation.
Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.
• For jump starting with cables in cold weather, refer

to the Operation and Maintenance Manual,
“Starting with Jump Start Cables.” for instructions.
SEBU9068 55
Viscosity of the Engine Lubrication Recommendations for Coolant

Oil Warm Up
Correct engine oil viscosity is essential. Oil viscosity Warm up an engine that has cooled below normal
affects the amount of torque that is needed to crank operating temperatures due to inactivity. This warm
the engine. Refer to this Operation and Maintenance -up should be performed before the engine is
Manual, “Fluid Recommendations” for the returned to full operation. During operation in very
recommended viscosity of oil. cold temperature conditions, damage to engine valve
mechanisms can result from engine operation for
Recommendations for the Coolant short intervals. This damage can happen if the engine
is started and the engine is stopped many times
Provide cooling system protection for the lowest without being operated in order to warm up
expected outside temperature. Refer to this completely.
Operation and Maintenance Manual, “Fluid
Recommendations” for the recommended coolant When the engine is operated below normal operating
mixture. temperatures, fuel and oil are not burned completely
In cold weather, check the coolant often for the in the combustion chamber. This fuel and oil causes
correct glycol concentration in order to ensure soft carbon deposits to form on the valve stems.
adequate freeze protection. Generally, the deposits do not cause problems and
the deposits are burned off during operation at normal
engine operating temperatures.
Engine Block Heaters
When starting and stopping an engine many times
Engine block heaters (if equipped) heat the engine without being operated in order to warm up
jacket water that surrounds the combustion completely, the carbon deposits become thicker. This
chambers. This heat provides the following functions: starting and stopping can cause the following
problems:
• Startability is improved.
• Free operation of the valves is prevented.
• Warm up time is reduced.
• Valves become stuck.
An electric block heater can be activated once the
engine is stopped. A block heater can be 110 V dc or • Pushrods may become bent.
240 V dc. The output can be 750/1000W. Consult
your Perkins distributor for more information. • Other damage to valve train components can
result.
Idling the Engine
For this reason, when the engine is started, the
After starting the engine, the engine speed will be engine must be operated until the coolant
held at low speed. The time held at low speed will temperature is 80° C (176° F) minimum. Carbon
depend on ambient temperature and time since last deposits on the valve stems will be kept at a minimum
run. The procedure is in order to allow the engine and the free operation of the valves and the valve
system to stabilize. When idling after the engine is components will be maintained.
started in cold weather, increase the engine rpm from
1000 to 1200 rpm. This idling will warm up the engine The engine must be thoroughly warmed in order to
more quickly. Maintaining an elevated low idle speed keep other engine parts in better condition. The
for extended periods will be easier with the service life of the engine will be generally extended.
installation of a hand throttle. The engine should not Lubrication will be improved. There will be less acid
be “raced” in order to speed up the warm-up process. and less sludge in the oil. This condition will provide
longer service life for the engine bearings, the piston
While the engine is idling, the application of a light rings, and other parts. However, limit unnecessary
load (parasitic load) will assist in achieving the idle time to 10 minutes in order to reduce wear and
minimum operating temperature. The minimum unnecessary fuel consumption.
operating temperature is 80° C (176° F).
56 SEBU9068
Radiator Restrictions
The Water Temperature Regulator and • High exhaust temperatures

Insulated Heater Lines • Power loss
The engine is equipped with a water temperature • Excessive fan usage
regulator. When the engine coolant is below the
correct operating temperature, jacket water circulates • Reduction in fuel economy
through the engine cylinder block and into the engine
cylinder head. The coolant then returns to the cylinder Reducing air flow over components will also affect
block via an internal passage that bypasses the valve under hood temperatures. Reducing air flow can
of the coolant temperature regulator. This return increase surface temperatures during an
ensures that coolant flows around the engine under aftertreatment regeneration and could affect
cold operating conditions. The water temperature component reliability.
regulator begins to open when the engine jacket
water has reached the correct minimum operating Reducing air flow can increase surface temperatures
temperature. As the jacket water coolant temperature during an aftertreatment regeneration and could
rises above the minimum operating temperature, the affect component reliability.
water temperature regulator opens further allowing
more coolant through the radiator to dissipate excess If an airflow restriction device must be used, the
heat. device should have a permanent opening directly in
line with the fan hub. The device must have a
The progressive opening of the water temperature minimum opening dimension of at least 770 cm2
regulator operates the progressive closing of the (120 in2).
bypass passage between the cylinder block and
head. This action ensures maximum coolant flow to A centered opening that is directly in line with the fan
the radiator in order to achieve maximum heat hub is specified in order to prevent an interrupted
dissipation. airflow on the fan blades. Interrupted airflow on the
fan blades could cause a fan failure.
Note: Do not restrict the air flow. Restriction of the air
flow can damage the fuel system. Perkins Perkins recommends a warning device for the inlet
discourages the use of all air flow restriction devices manifold temperature and/or the installation of an inlet
such as radiator shutters. Restriction of the air flow air temperature gauge. The warning device for the
can result in the following: high exhaust inlet manifold temperature should be set at 75 °C
temperatures, power loss, excessive fan usage and (167 °F). The inlet manifold air temperature should
reduction in fuel economy. not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential
A cab heater is beneficial in very cold weather. The engine damage.
feed from the engine and the return lines from the cab
should be insulated in order to reduce heat loss to the i05849931
outside air.
Fuel and the Effect from Cold
Recommendation for Crankcase Breather
Protection Weather
Crankcase ventilation gases can contain a large
quantity of water vapor. This water vapor can freeze Note: Only use grades of fuel that are recommended
in cold ambient conditions and can plug or damage by Perkins. Refer to this Operation and Maintenance
the crankcase ventilation system. Manual, “Fluid Recommendations”.
The breather heater or other breather thermal Properties of the diesel fuel can have a significant
protection is important and any OEM equipment must effect on the engine cold start capability. It is critical
be operational to prevent the risk of breather freezing that the low temperature properties of diesel fuel are
for operation below −5° C (23° F). acceptable for the minimum ambient temperature the
engine is expected to see in the operation.
i05203509
Following properties are used to define fuels low
temperature capability:
Radiator Restrictions
• Cloud point
Perkins discourages the use of airflow restriction • Pour point

devices that are mounted in front of radiators. Airflow
restriction can cause the following conditions: • Cold Filter Plugging Point (CFPP)
SEBU9068 57
Fuel Related Components in Cold Weather
The cloud point of the fuel is the temperature at which Drain the water and sediment from any fuel storage
waxes naturally found in the diesel fuel begin to form tank at the following intervals: weekly, service
crystals. The cloud point of the fuel must be below intervals and refueling of the fuel tank. Draining will
lowest ambient temperature to prevent filters from help prevent water and/or sediment from being
plugging. pumped from the fuel storage tank and into the
engine fuel tank.
Cold Filter Plugging Point is a temperature at which a
particular fuel will pass through a standardized Fuel Filters
filtration device. This CFPP gives an estimate of the
lower operability temperature of fuel After you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
Pour point is the last temperature before the fuel flow system. Refer to the Operation and Maintenance
stops and waxing of the fuel will start. Manual in the Maintenance Section for more
information on priming the fuel system.
Be aware of these properties when diesel fuel is
purchased. Consider the average ambient air The micron rating and the location of a primary fuel
temperature for the engines application. Engines that filter is important in cold-weather operation. The In-
are fueled in one climate may not operate well if the line filter, primary fuel filter, and the fuel supply line
engines are shipped to colder climate. Problems can are the most common components that are affected
result due to changes in temperature. by cold fuel.
Before troubleshooting for low power or for poor Fuel Heaters
performance in the winter, check the fuel for waxing
Note: The OEM may equip the application with fuel
The following components can provide a means of heaters. If so, the temperature of the fuel must not
minimizing fuel waxing problems in cold weather:
exceed 73 °C (163 °F) at the fuel transfer pump. The
• Fuel heaters, which may be an OEM option fuel heater should be installed before the electric lift
pump.
• Fuel line insulation, which may be an OEM option
For more information about fuel heaters (if equipped),
Winter and arctic grades of diesel fuel are available in refer to the OEM information.
the countries and territories with severe winters. For
more information refer to the Operation and i05769085
Maintenance Manual, “Fuel For Cold Weather
Operation”
Diesel Exhaust Fluid in Cold
Another important fuel property which can affect cold
start and operation of diesel engine is Cetane Weather
number. Detail and requirements of this property are
given in this Operation and Maintenance Manual,
“Fluid Recommendations”. Due to the freezing point of Diesel Exhaust Fluid
(DEF) the aftertreatment system is equipped with
i05359588
electrically heated DEF lines. The system also has a
coolant heated element in the DEF tank.
Fuel Related Components in During periods of weather in which DEF can freeze
the application should be stood on level ground when
Cold Weather not in use. DEF can start to freeze at −11° C
(12.2° F).
Note: At certain angles DEF can cover the DEF filler
Fuel Tanks cap. If the DEF freezes, the DEF tank vent could
block. A blocked vent in the DEF tank assembly will
Condensation can form in partially filled fuel tanks.
course operational difficulties.
Top off the fuel tanks after you operate the engine.
For information on DEF refer to this Operation and
Fuel tanks should contain some provision for draining
Maintenance Manual, “Fluid Recommendations”.
water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
58 SEBU9068
Engine Stopping
Stopping the Engine
Engine Stopping Emergency Stop Button
i05856294
Stopping the Engine
NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac-
celerated wear of the engine components.
Avoid accelerating the engine prior to shutting it
down.
Avoiding hot engine shutdowns will maximize turbo- Illustration 30 g00104303
charger shaft and bearing life.
Typical emergency stop button
Note: Individual applications will have different The emergency stop button is in the OUT position for
control systems. Ensure that the shutoff procedures normal engine operation. Push the emergency stop
button. The engine will not start when the button is
are understood. Use the following general guidelines
locked. Turn the button clockwise in order to reset.
in order to stop the engine.
Refer to Operation and Maintenance Manual,
1. Remove the load from the engine. Reduce the “Features and Controls” for the location and the
engine speed (rpm) to low idle. Allow the engine to operation of the emergency stop button.
idle for 5 minutes in order to cool the engine.
i05856324
2. Stop the engine after the cool down period
according to the shutoff system on the engine and After Stopping Engine
turn the ignition key switch to the OFF position. If
necessary, refer to the instructions that are
provided by the OEM.
3. Allow 2 minutes after the engine has stopped

before you turn the battery disconnect switch to Contact with high pressure fuel may cause fluid
OFF. Disconnecting the battery power too soon will penetration and burn hazards. High pressure fuel
prevent purging of the diesel exhaust fluid lines spray may cause a fire hazard. Failure to follow
after the engine is shut down. these inspection, maintenance and service in-
i03554860
Emergency Stopping
NOTICE
Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices
or controls for normal stopping procedure.
Ensure that any components for the external system

that support the engine operation are secured after
the engine is stopped.
SEBU9068 59
Engine Stopping
After Stopping Engine
• Diesel Exhaust Fluid (DEF) purge, do not • Allow the engine to cool. Check the coolant level.
disconnect the battery disconnect switch until the
DEF purge has been completed. The procedure is • Check the coolant for correct antifreeze protection
automatically controlled and will take and the correct corrosion protection. Add the
approximately 2 minutes. correct coolant/water mixture, if necessary.
• After the engine has stopped, you must wait for 10 • Perform all required periodic maintenance on all
minutes in order to allow the fuel pressure to be driven equipment. This maintenance is outlined in
purged from the high-pressure fuel lines before the instructions from the OEM.
any service or repair is performed on the engine
fuel lines. The 10 minute wait will also allow static
charge to dissipate from the low-pressure fuel
system. If necessary, perform minor adjustments.
Repair any leaks from the low-pressure fuel
system and from the cooling, lubrication, or air
systems. Replace any high-pressure fuel line that
has leaked. Refer to Disassembly and Assembly
Manual, “Fuel Injection Lines - Install”.
• Before you check the engine oil, do not operate the
engine. Wait for at least 10 minutes after the
engine has stopped in order to allow the engine oil
to return to the oil pan. Check the crankcase oil
level. Maintain the oil level between the “MIN”
mark and the “MAX” mark on the engine oil level
gauge.
• If the engine is equipped with a service hour meter,

note the reading. Perform the maintenance that is
in the Operation and Maintenance Manual,
“Maintenance Interval Schedule”.
• Fill the fuel tank, in order to help prevent

accumulation of moisture in the fuel. Do not overfill
the fuel tank.
• Fill the DEF tank, a low level of DEF in the tank
can result in engine de-rate.
NOTICE
Only use antifreeze/coolant mixtures recommended
in this Operation and Maintenance Manual, “Refill Ca-
pacities and Recommendations” topic or in this Oper-
ation and Maintenance Manual, “Fluid
Recommendations” topic. Failure to do so can cause
engine damage.
Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
60 SEBU9068
Maintenance Section
Refill Capacities
Maintenance Section
Refill Capacities
i05962392
Refill Capacities
Lubrication System
The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will
require additional oil. Refer to the Original Equipment
Manufacture (OEM) specifications for the capacity of
the auxiliary oil filter. Refer to the Operation and
Maintenance Manual, “Maintenance Section” for
more information on Lubricant Specifications.
Table 9
Engine
Refill Capacities
Maximum
Compartment or System Minimum(1) (2)
6L 8.5 L
Crankcase Oil Sump
(1.58 US gal) (2.2 US gal)
(1) The minimum value is the approximate capacity for the crank-
case oil sump (aluminum) which includes the standard factory
installed oil filters. Engines with auxiliary oil filters will require ad-
ditional oil. Refer to the OEM specifications for the capacity of
the auxiliary oil filter. The design of the oil pan can change the
oil capacity of the oil pan.
(2) Approximate capacity of the largest crankcase oil sump. Refer
to OEM for more information.
Cooling System
Refer to the OEM specifications for the External
System capacity. This capacity information will be
needed in order to determine the amount of coolant/
antifreeze that is required for the Total Cooling
System.
Table 10
Engine
Refill Capacities
Compartment or System Liters
Engine only 6 L (1.5 US gal)
Radiator only 8.7 L (2.3 US gal)
External System Per OEM(1) -

(1) The External System includes coolant connection hoses and aftertreatment system.
Diesel Exhaust Fluid (DEF)

The DEF tank capacity for the loose industrial engine
is 19 L (5 US gal).
SEBU9068 61
Refill Capacities
Fluid Recommendations
i05859331 Engine Oil

Fluid Recommendations Commercial Oils
NOTICE
General Lubricant Information Perkins require the use of the following specifica-
tion of engine oil. Failure to use the appropriate
Because of government regulations regarding the specification of engine oil will reduce the life of
certification of exhaust emissions from the engine, the your engine. Failure to use the appropriate speci-
lubricant recommendations must be followed. fication of engine oil will also reduce the life of
your aftertreatment system.
• API American Petroleum Institute
• SAE Society Of Automotive Engineers Inc. Table 11

Classifications for the 854 Industrial Engine
• ACEA Association des Constructers
European Automobiles. Oil Specification
API CJ-4
• ECF-3 Engine Crankcase Fluid
ACEA E9
ECF-3
Licensing
API CJ-4 and ACEA E9 oil categories have the
The Engine Oil Licensing and Certification System by following chemical limits:
the American Petroleum Institute (API) and the
Association des Constructers European • 0.1 percent maximum sulfated ash
Automobilesand (ACRA) is recognized by Perkins .
For detailed information about this system, see the • 0.12 percent maximum phosphorous
latest edition of the “API publication No. 1509”.
Engine oils that bear the API symbol are authorized • 0. 4 percent maximum sulfur
by API.
Maintenance intervals for engines that use
biodiesel – The oil change interval can be adversely
affected by the use of biodiesel. Use oil analysis in
order to monitor the condition of the engine oil. Use
oil analysis also in order to determine the oil change
interval that is optimum.
Note: These engine oils are not approved by

Perkins and these engine oils must not be used:
CC, CD, CD-2, CF-4, CG-4, CH-4 and CI-4.
Lubricant Viscosity Recommendations

for Direct Injection (DI) Diesel Engines
Illustration 31 g01987816 The correct SAE viscosity grade of oil is determined
Typical API symbol by the minimum ambient temperature during cold
engine start-up, and the maximum ambient
temperature during engine operation.
Terminology
Refer to illustration 32 (minimum temperature) in
Certain abbreviations follow the nomenclature of order to determine the required oil viscosity for
“SAE J754”. Some classifications follow “SAE J183” starting a cold engine.
abbreviations, and some classifications follow the
“EMA Recommended Guideline on Diesel Engine Refer to illustration 32 (maximum temperature) in
Oil”. In addition to Perkins definitions, there are other order to select the oil viscosity for engine operation at
definitions that will be of assistance in purchasing the highest ambient temperature that is anticipated.
lubricants. Recommended oil viscosities can be
found in this publication, “Fluid Recommendations/ Generally, use the highest oil viscosity that is
Engine Oil” topic (Maintenance Section). available to meet the requirement for the temperature
at start-up.
62 SEBU9068
Refill Capacities
• See the appropriate “Lubricant Viscosities”. Refer

to the illustration 32 in order to find the correct oil
viscosity grade for your engine.
• At the specified interval, service the engine. Use

new oil and install a new oil filter.
• Perform maintenance at the intervals that are

specified in the Operation and Maintenance
Manual, “Maintenance Interval Schedule”.
Oil analysis
Some engines may be equipped with an oil sampling
valve. If oil analysis is required, the oil sampling valve
is used to obtain samples of the engine oil. The oil
analysis will complement the preventive maintenance
program.
The oil analysis is a diagnostic tool that is used to
determine oil performance and component wear
rates. Contamination can be identified and measured
by using oil analysis. The oil analysis includes the
following tests:
Lubricant Viscosities
Supplemental heat is recommended for cold soaked • The Wear Rate Analysis monitors the wear of the
starts below the minimum ambient temperature. engines metals. The amount of wear metal and
Supplemental heat may be required for cold soaked type of wear metal that is in the oil is analyzed. The
starts that are above the minimum temperature that is increase in the rate of engine wear metal in the oil
stated, depending on the parasitic load and other is as important as the quantity of engine wear
factors. Cold soaked starts occur when the engine metal in the oil.
has not been operated over a period of time. This
interval will allow the oil to become more viscous due • Tests are conducted in order to detect
to cooler ambient temperatures. contamination of the oil by water, glycol, or fuel.
Aftermarket Oil Additives • The Oil Condition Analysis determines the loss of
the oils lubricating properties. An infrared analysis
Perkins does not recommend the use of aftermarket is used to compare the properties of new oil to the
additives in oil. It is not necessary to use aftermarket properties of the used oil sample. This analysis
additives in order to achieve the engines maximum allows technicians to determine the amount of
service life or rated performance. Fully formulated, deterioration of the oil during use. This analysis
finished oils consist of base oils and of commercial also allows technicians to verify the performance
additive packages. These additive packages are
blended into the base oils at precise percentages in of the oil according to the specification during the
order to help provide finished oils with performance entire oil change interval.
characteristics that meet industry standards.
i04358959
There are no industry standard tests that evaluate the
performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may not
be compatible with the finished oils additive package,
which could lower the performance of the finished oil. General Coolant Information
The aftermarket additive could fail to mix with the
finished oil. This failure could produce sludge in the
crankcase. Perkins discourages the use of
aftermarket additives in finished oils. NOTICE
Never add coolant to an overheated engine. Engine
To achieve the best performance from a Perkins
engine, conform to the following guidelines: damage could result. Allow the engine to cool first.
SEBU9068 63
Refill Capacities
Table 12
NOTICE
If the engine is to be stored in, or shipped to an area Acceptable Water
with below freezing temperatures, the cooling system
Property Maximum Limit
must be either protected to the lowest outside temper-
ature or drained completely to prevent damage. Chloride (Cl) 40 mg/L
Sulfate (SO4) 100 mg/L

NOTICE Total Hardness 170 mg/L
Frequently check the specific gravity of the coolant for
proper freeze protection or for anti-boil protection. Total Solids 340 mg/L
Acidity pH of 5.5 to 9.0

Clean the cooling system for the following reasons:
For a water analysis, consult one of the following
• Contamination of the cooling system sources:
• Overheating of the engine • Local water utility company
• Foaming of the coolant • Agricultural agent
NOTICE • Independent laboratory

Never operate an engine without water temperature
regulators in the cooling system. Water temperature Additives
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob- Additives help to protect the metal surfaces of the
lems can develop without water temperature cooling system. A lack of coolant additives or
regulators. insufficient amounts of additives enable the following
conditions to occur:
Many engine failures are related to the cooling • Corrosion

system. The following problems are related to cooling
system failures: Overheating, leakage of the water • Formation of mineral deposits
pump and plugged radiators or heat exchangers.
• Rust
These failures can be avoided with correct cooling
system maintenance. Cooling system maintenance is • Scale
as important as maintenance of the fuel system and
the lubrication system. Quality of the coolant is as • Foaming of the coolant
important as the quality of the fuel and the lubricating
oil. Many additives are depleted during engine operation.
These additives must be replaced periodically.
Coolant is normally composed of three elements:
Water, additives and glycol. Additives must be added at the correct concentration.
Over concentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can
Water enable the following problems to occur:
Water is used in the cooling system in order to • Formation of gel compounds
transfer heat.
• Reduction of heat transfer
Distilled water or deionized water is
recommended for use in engine cooling systems. • Leakage of the water pump seal
DO NOT use the following types of water in cooling • Plugging of radiators, coolers, and small passages
systems: Hard water, softened water that has been
conditioned with salt and sea water.
Glycol
If distilled water or deionized water is not available,
use water with the properties that are listed in Table Glycol in the coolant helps to provide protection
12 . against the following conditions:
64 SEBU9068
Refill Capacities
• Boiling
NOTICE
• Freezing The 854 industrial engines must be operated with
a 1:1 mixture of water and glycol. This concentra-
• Cavitation of the water pump tion allows the NOx reduction system to operate
correctly at high ambient temperatures.
For optimum performance, Perkins recommends a
1:1 mixture of a water/glycol solution.
NOTICE
Note: Use a mixture that will provide protection
Do not use a commercial coolant/antifreeze that only
against the lowest ambient temperature.
meets the ASTM D3306 specification. This type of
Note: 100 percent pure glycol will freeze at a coolant/antifreeze is made for light automotive
temperature of −13 °C (8.6 °F). applications.
Most conventional antifreezes use ethylene glycol.

Propylene glycol may also be used. In a 1:1 mixture Perkins recommends a 1:1 mixture of water and
glycol. This mixture of water and glycol will provide
with water, ethylene and propylene glycol provide
optimum heavy-duty performance as an antifreeze.
similar protection against freezing and boiling. Refer
This ratio may be increased to 1:2 water to glycol if
to Table 13 and refer to table 14 .
extra freezing protection is required.
Table 13
Ethylene Glycol A mixture of SCA inhibitor and water is acceptable
but will not give the same level of corrosion, boiling
Concentration Freeze Protection and, freezing protection as ELC. Perkins
recommends a 6 percent to 8 percent concentration
50 Percent −36 °C (−33 °F)
of SCA in those cooling systems. Distilled water or
60 Percent −51 °C (−60 °F) deionized water is preferred. Water which has the
recommended properties may be used.
Table 15
NOTICE Coolant Service Life
Do not use propylene glycol in concentrations that ex-
Coolant Type Service Life (1)
ceed 50 percent glycol because of the reduced heat
transfer capability of propylene glycol. Use ethylene 6,000 Service Hours or Three
Perkins ELC
glycol in conditions that require additional protection Years
against boiling or freezing. Commercial Heavy-Duty Anti-
freeze that meets “ASTM 3000 Service Hours or Two Year
Table 14 D6210”
Propylene Glycol Commercial SCA inhibitor and
3000 Service Hours or One Year
Water
Concentration Freeze Protection
(1) Use the interval that occurs first. The cooling system must also
50 Percent −29 °C (−20 °F) be flushed out at this time.
To check the concentration of glycol in the coolant, ELC

measure the specific gravity of the coolant.
Perkins provides ELC for use in the following
Coolant Recommendations applications:
• Heavy-duty spark ignited gas engines
• ELC Extended Life Coolant
• Heavy-duty diesel engines
• SCA Supplement Coolant Additive
• Automotive applications
• ASTM American Society for Testing and
Materials The anti-corrosion package for ELC is different from
The following two coolants are used in Perkins the anti-corrosion package for other coolants. ELC is
diesel engines: an ethylene glycol base coolant. However, ELC
contains organic corrosion inhibitors and antifoam
Preferred – Perkins ELC agents with low amounts of nitrite. Perkins ELC has
been formulated with the correct amount of these
additives in order to provide superior corrosion
Acceptable – A commercial heavy-duty antifreeze protection for all metals in engine cooling systems.
that meets “ASTM D6210” specifications
SEBU9068 65
Refill Capacities
ELC is available in a premixed cooling solution with Before the cooling system is filled, the heater control
distilled water. ELC is a 1:1 mixture. The Premixed (if equipped) must be set to the HOT position. Refer
ELC provides freeze protection to −36 °C (−33 °F). to the OEM in order to set the heater control. After the
The Premixed ELC is recommended for the initial fill cooling system is drained and the cooling system is
of the cooling system. The Premixed ELC is also refilled, operate the engine until the coolant level
recommended for topping off the cooling system. reaches the normal operating temperature and until
the coolant level stabilizes. As needed, add the
Containers of several sizes are available. Consult coolant mixture in order to fill the system to the
your Perkins distributor for the part numbers. specified level.
ELC Cooling System Maintenance Changing to Perkins ELC
Correct additions to the Extended Life To change from heavy-duty antifreeze to the Perkins
Coolant ELC, perform the following steps:
NOTICE
NOTICE Care must be taken to ensure that all fluids are con-
Use only Perkins products for pre-mixed or concen- tained during performance of inspection, mainte-
trated coolants. nance, testing, adjusting and the repair of the
Mixing Extended Life Coolant with other products re- product. Be prepared to collect the fluid with suitable
duces the Extended Life Coolant service life. Failure containers before opening any compartment or disas-
to follow the recommendations can reduce cooling sembling any component containing fluids.
system components life unless appropriate corrective
action is performed. Dispose of all fluids according to local regulations and
mandates.
In order to maintain the correct balance between the

antifreeze and the additives, you must maintain the 1. Drain the coolant into a suitable container.
recommended concentration of ELC. Lowering the
proportion of antifreeze lowers the proportion of 2. Dispose of the coolant according to local
additive. This will lower the ability of the coolant to regulations.
protect the system from pitting, from cavitation, from
erosion, and from deposits. 3. Flush the system with clean water in order to
remove any debris.
NOTICE
Do not use a conventional coolant to top-off a cooling 4. Use an appropriate cleaner to clean the system.
system that is filled with Extended Life Coolant (ELC). Follow the instruction on the label.
Do not use standard supplemental coolant additive 5. Drain the cleaner into a suitable container. Flush
(SCA). the cooling system with clean water.
When using Perkins ELC, do not use standard SCA's 6. Fill the cooling system with clean water and
or SCA filters. operate the engine until the engine is warmed to
49° to 66°C (120° to 150°F).
ELC Cooling System Cleaning
NOTICE
Note: If the cooling system is already using ELC, Incorrect or incomplete flushing of the cooling system
cleaning agents are not required to be used at the can result in damage to copper and other metal
specified coolant change interval. Cleaning agents components.
are only required if the system has been
contaminated by the addition of some other type of To avoid damage to the cooling system, make sure to
coolant or by cooling system damage. completely flush the cooling system with clear water.
Continue to flush the system until all the signs of the
Clean water is the only cleaning agent that is required cleaning agent are gone.
when ELC is drained from the cooling system.
7. Drain the cooling system into a suitable container
and flush the cooling system with clean water.
66 SEBU9068
Refill Capacities
Note: The cooling system cleaner must be thoroughly

NOTICE
flushed from the cooling system. Cooling system
cleaner that is left in the system will contaminate the Never operate an engine without water temperature
regulators in the cooling system. Water temperature
coolant. The cleaner may also corrode the cooling
regulators help to maintain the engine coolant at the
system.
correct operating temperature. Cooling system prob-
8. Repeat Steps 6 and repeat steps 7 until the system lems can develop without water temperature
is completely clean. regulators.
9. Fill the cooling system with the Perkins Premixed
ELC. Check the antifreeze (glycol concentration) in order to
ensure adequate protection against boiling or
ELC Cooling System Contamination freezing. Perkins recommends the use of a
refractometer for checking the glycol concentration. A
hydrometer should not be used.
NOTICE
Mixing ELC with other products reduces the effective- Perkins engine cooling systems should be tested at
ness of the ELC and shortens the ELC service life. 500 hour intervals for the concentration of SCA.
Use only Perkins Products for premixed or concen- Additions of SCA are based on the results of the test.
trate coolants. Failure to follow these recommenda- An SCA that is liquid may be needed at 500 hour
tions can result in shortened cooling system intervals.
component life.
Adding the SCA to Heavy-Duty Coolant at
ELC cooling systems can withstand contamination to the Initial Fill
a maximum of 10 percent of conventional heavy-duty
antifreeze or SCA. If the contamination exceeds 10 Use the equation that is in Table 16 to determine the
percent of the total system capacity, perform ONE of amount of SCA that is required when the cooling
the following procedures: system is initially filled.
Table 16
• Drain the cooling system into a suitable container.
Dispose of the coolant according to local Equation For Adding The SCA To The Heavy-Duty Coolant At
regulations. Flush the system with clean water. Fill The Initial Fill
the system with the Perkins ELC. V × 0.045 = X
• Drain a portion of the cooling system into a V is the total volume of the cooling system.
suitable container according to local regulations. X is the amount of SCA that is required.
Then, fill the cooling system with premixed ELC.
This procedure should lower the contamination to
less than 10 percent. Table 17 is an example for using the equation that is
in Table 16 .
• Maintain the system as a conventional Heavy-Duty Table 17
Coolant. Treat the system with an SCA. Change Example Of The Equation For Adding The SCA To The Heavy-
the coolant at the interval that is recommended for Duty Coolant At The Initial Fill
the conventional Heavy-Duty Coolant.
Total Volume of the Multiplication Amount of SCA
Cooling System (V) Factor that is Required (X)
Commercial Heavy-Duty Antifreeze and
15 L (4 US gal) × 0.045 0.7 L (24 oz)
SCA
NOTICE Adding The SCA to The Heavy-Duty

Commercial Heavy-Duty Coolant which contains
Amine as part of the corrosion protection system must
Coolant For Maintenance
not be used. Heavy-duty antifreeze of all types REQUIRE periodic
additions of an SCA.
Test the antifreeze periodically for the concentration
of SCA. For the interval, refer to the Operation and
Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section). Cooling System
Supplemental Coolant Additive (SCA) Test/Add.
SEBU9068 67
Refill Capacities
Additions of SCA are based on the results of the test. The document series ISO standard 22241 will give
The size of the cooling system determines the information on quality requirements, test methods,
amount of SCA that is needed. handling, transportation, storage, and refilling
interface.
Use the equation that is in Table 18 to determine the
amount of SCA that is required, if necessary:
Table 18
Spillage
Equation For Adding The SCA To The Heavy-Duty Coolant For Care should be taken when dispensing DEF. Spills
Maintenance should be cleaned immediately. All surfaces should
V × 0.014 = X be wiped clean and rinsed with water.
V is the total volume of the cooling system. DEF that has been split will crystallize when the water
within the liquid evaporates. Spilt DEF will attack
X is the amount of SCA that is required. paint and metal. If DEF is split, wash the area with
water.
Table 19 is an example for using the equation that is Caution should be used when dispensing DEF near
in Table 18 . an engine that has recently been running. Spilling
Table 19 DEF onto hot components may cause the release of
Example Of The Equation For Adding The SCA To The Heavy- ammonia vapors. Do not breathe ammonia vapors.
Duty Coolant For Maintenance Do not clean up any spills with bleach.
Total Volume of the Multiplication Amount of SCA

Cooling System (V) Factor that is Required (X)
Filling the DEF Tank
15 L (4 US gal) × 0.014 0.2 L (7 oz) The fill cap on the DEF tank must be colored blue.
The DEF level is important, allowing the DEF tank to
run dry or operate at a low level can affect the engine
Cleaning the System of Heavy-Duty operation. Because of the corrosive nature of DEF,
the correct materials must be used when filling a DEF
Antifreeze tank.
• Clean the cooling system after used coolant is DEF Quality

drained or before the cooling system is filled with
new coolant. The quality of DEF can be measured by using a
refractometer. The DEF must comply with ISO
• Clean the cooling system whenever the coolant is standard 22241-1 with the urea solution of 32.5
contaminated or whenever the coolant is foaming. percent. Perkins offer a T400195 Refractometer for
checking the concentration of the DEF.
i05810173
Cleanliness
Fluid Recommendations Contaminants can degrade the quality and life of
(Diesel Exhaust Fluid (DEF)) DEF. Filtering DEF is recommended when dispensed
into the DEF tank. Filters should be compatible with
DEF and should be used exclusively with DEF. Check
with the filter supplier to confirm compatibility with
General Information DEF before using. Mesh-type filters using compatible
metals, such as stainless steel, are recommended.
Diesel Exhaust Fluid (DEF) is a liquid that is injected Paper (cellulose) media and some synthetic filter
into the aftertreatment system before Selective media are not recommended because of degradation
Catalytic Reduction (SCR). This system of injecting during use.
the DEF into the exhaust will reactor in the SCR
system. The Nitrogen Oxide (NOx) molecules in the Care should be taken when dispensing DEF. Spills
exhaust are converted to elemental nitrogen and should be cleaned immediately. Machine or engine
water. This conversion will reduce the emission of the surfaces should be wiped clean and rinsed with
engine. water. Caution should be used when dispensing DEF
near an engine that has recently been running.
Specification Spilling DEF onto hot components will cause harmful
vapors.
DEF that is used in Perkins engines must meet the
ISO specification 22241-1 for quality. The ISO Storage
specification 22241-1 requirements are met by many
brands of DEF, including those that carry the AdBlue Do not store DEF in direct sunlight.
or API certification."
68 SEBU9068
Refill Capacities
Table 20 i05859273
Storage Temperature Expected DEF Life

Below 25° C (77° F) 18 months
25° C (77° F) to 30° C (86° F) 12 months

• Glossary
30° C (86° F) to 35° C (95° F) 6 months
Above 35° C (95° F) test quality before use

• ISO International Standards Organization
• ASTM American Society for Testing and

Perkins recommend that all DEF taken from storage Materials
should be checked to ensure the DEF meets ISO
standard 22241-1. • HFRR High Frequency Reciprocating Rig
for Lubricity testing of diesel fuels
Materials compatibility
• FAME Fatty Acid Methyl Esters
DEF is corrosive. Due to the corrosion caused, DEF
must be stored in tanks constructed of approved • CFR Co-ordinating Fuel Research
materials. Recommended storage materials:
• ULSD Ultra Low Sulfur Diesel
Stainless Steels:
• RME Rape Methyl Ester
• 304 (S30400)
• SME Soy Methyl Ester
• 304L (S30403)
• EPA Environmental Protection Agency of
• 316 (S31600) the United States
• 316L (S31603) • PPM Parts Per Million
Alloys and metals: General Information

• Chromium Nickel (CrNi) NOTICE
Every attempt is made to provide accurate, up-to-date
• Chromium Nickel Molybdenum (CrNiMo)
information. By use of this document you agree that
• Titanium Perkins Engines Company Limited is not responsible
for errors or omissions.
Non-metallic materials:
• Polyethylene NOTICE
These recommendations are subject to change with-
• Polypropylene
out notice. Contact your local Perkins distributor for
• Polyisobutylene the most up-to-date recommendations.
• Teflon (PFA)
Diesel Fuel Requirements
• Polyfluoroethylene (PFE)
Perkins is not in a position to continuously evaluate
• Polyvinylidene fluoride (PVDF) and monitor all worldwide distillate diesel fuel
specifications that are published by governments and
• Polytetrafluoroethylene (PTFE) technological societies.
Materials NOT compatible with DEF solutions include The PerkinsSpecification for Distillate Diesel Fuel
Aluminum, Magnesium, Zinc, Nickel coatings, Silver provides a known reliable baseline in order to judge
and Carbon steel and Solders containing any of the the expected performance of distillate diesel fuels that
above. Unexpected reactions may occur if DEF are derived from conventional sources.
solutions come in contact with any non-compatible
material or unknown materials. Satisfactory engine performance is dependent on the
use of a good quality fuel. The use of a good quality
fuel will give the following results: long engine life and
acceptable exhaust emissions levels. The fuel must
meet the minimum requirements that are stated in the
table 21 .
SEBU9068 69
Refill Capacities
NOTICE
The footnotes are of the key partPerkins Specification
for Distillate Diesel Fuel Table. Read ALL of the
footnotes.
Table 21
Perkins Specification for Distillate Diesel Fuel(1)
Property UNITS Requirements “ASTM”Test “ISO”Test
Aromatics %Volume 35% maximum D1319 “ISO”3837

Ash %Weight 0.01% maximum D482 “ISO”6245
Carbon Residue on 10% %Weight 0.35% maximum D524 “ISO”4262

Bottoms
Cetane Number (2) - 40 minimum D613/D6890 “ISO”5165
Cloud Point °C The cloud point must not ex- D2500 “ISO”3015
ceed the lowest expected
ambient temperature.
Copper Strip Corrosion - No. 3 maximum D130 “ISO”2160

3
Density at 15 °C (59 °F)(3) kg/m 801 minimum and 876 No equivalent test “ISO 3675” “ISO 12185”
maximum
Distillation °C 10% at 282 °C (539.6 °F) D86 “ISO”3405
maximum
90% at 360 °C (680 °F)
maximum
Flash Point °C legal limit D93 “ISO”2719
Thermal Stability - Minimum of 80% reflectance D6468 No equivalent test

after aging for 180 minutes
at 150 °C (302 °F)
Pour Point °C 6 °C (42.8 °F) minimum be- D97 “ISO”3016

low ambient temperature
Sulfur (1) %mass 0.0015 D5453/D26222 “ISO 20846” “ISO 20884”
Kinematic Viscosity (4) mm2/s (cSt) The viscosity of the fuel that D445 “ISO”3405
is delivered to the fuel injec-
tion pump. “1.4 minimum/
4.5 maximum”
Water and sediment % weight 0.1% maximum D1796 “ISO”3734
Water % weight 0.1% maximum D1744 No equivalent test
Sediment % weight 0.05% maximum D473 “ISO”3735
Gums and Resins(5) mg/100mL 10 mg per 100 mL D381 “ISO”6246

maximum
Lubricity corrected wear mm 0.52 maximum D6079 “ISO”12156-1
scar diameter at 60 °C
(140 °F). (6)
(1) This specification includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to
“ASTM D5453”, “ASTM D2622”, or “ISO 20846, ISO 20884” test methods.
(2) A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather.
(3) “Via standards tables, the equivalent API gravity for the minimum density of 801 kg / m3 (kilograms per cubic meter) is 45 and for the maximum
density of 876 kg / m3 is 30”.
(continued)
70 SEBU9068
Refill Capacities
(Table 21, contd)

(4) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscosity
requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the “ASTM D445” test method or the
“ISO 3104” test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain “1.4 cSt”or greater viscosity at the
fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to “1.4 cSt” at the fuel injection pump.
(5) Follow the test conditions and procedures for gasoline (motor).
(6) The lubricity of a fuel is a concern with ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or ASTM D6079 High
Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supplier. Do not
treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system.
Engines that are manufactured by Perkins are The fuel specifications that are listed in the table 22
certified with the fuel that is prescribed by the United are released as acceptable to use on all 854
States Environmental Protection Agency. Engines industrial engine.
that are manufactured by Perkins are certified with
the fuel that is prescribed by the European
Certification. Perkins does not certify diesel engines
on any other fuel.
Note: The owner and the operator of the engine has

the responsibility of using the fuel that is prescribed
by the EPA and other appropriate regulatory
agencies.
NOTICE
Operating with fuels that do not meet the Perkins rec-
ommendations can cause the following effects: Start-
ing difficulty, reduced fuel filter service life, poor
combustion, deposits in the fuel injectors, significantly
reduce service life of the fuel system, deposits in the
combustion chamber and reduced service life of the
engine.
NOTICE
The Perkins 854 industrial engine must be operated
using Ultra Low Sulfur Diesel. The sulphur content of
this fuel must be lower than 15 PPM. This fuel com-
plies with the emissions regulations that are pre-
scribed by the Environmental Protection Agency of
the United States.
Illustration 33 is a representation of the label that will

be installed next to the fuel filler cap on the fuel tank
of the application.
SEBU9068 71
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Table 22
Acceptable Fuel Specification for the 854 industrial Engine(1)
Fuel Specification Comments
EN590 European Automotive Diesel Fuel (DERV)
“ASTM D975 GRADE 1D S15” “North American Light Distillate Diesel fuel with less than 15 PPM sulfur
level”
“ASTM D975 GRADE 2D S15” “North American Middle Distillate general purpose Diesel fuel with less
than 15 PPM sulfur level”
“JIS K2204” “Japanese Diesel Fuel” Must meet the requirements that are stated in
the section “Lubricity”.
“BS 2869: 2010 CLASS A2 or EU equivalent” “EU Off Road Diesel fuel. Acceptable from 2011 MUST have less than
10 PPM sulfur level”
(1) All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel.
Diesel Fuel Characteristics The viscosity of the fuel is significant because fuel
serves as a lubricant for the fuel system components.
Cetane Number Fuel must have sufficient viscosity in order to
lubricate the fuel system in both extremely cold
Fuel that has a high cetane number will give a shorter
temperatures and extremely hot temperatures. If the
ignition delay. A high cetane number will produce a
kinematic viscosity of the fuel is lower than “1.4 cSt”
better ignition quality. Cetane numbers are derived for
at the fuel injection pump, damage to the fuel injection
fuels against proportions of cetane and pump can occur. This damage can be excessive
heptamethylnonane in the standard CFR engine.
scuffing and seizure. Low viscosity may lead to
Refer to “ISO 5165” for the test method. difficult hot restarting, stalling, and loss of
Cetane numbers in excess of 45 are normally performance. High viscosity may result in seizure of
expected from current diesel fuel. However, a cetane the pump.
number of 40 may be experienced in some territories.
The United States of America is one of the territories Perkins recommends kinematic viscosities of 1.4 and
that can have a low cetane value. A minimum cetane 4.5 mm2/sec that is delivered to the fuel injection
value of 40 is required during average starting pump. If a fuel with a low viscosity is used, cooling of
conditions. A fuel with higher cetane number is the fuel may be required to maintain 1.4 cSt or
recommended for operations at high altitudes or in greater viscosity at the fuel injection pump. Fuels with
cold-weather operations. a high viscosity might require fuel heaters in order to
lower the viscosity to 4.5 cSt at the fuel injection
Fuel with a low cetane number can be the root cause pump.
of problems during a cold start.
Density
Viscosity
Density is the mass of the fuel per unit volume at a
Viscosity is the property of a liquid of offering specific temperature. This parameter has a direct
resistance to shear or flow. Viscosity decreases with influence on engine performance and a direct
increasing temperature. This decrease in viscosity influence on emissions. This influence determines
follows a logarithmic relationship for normal fossil from a heat output given injected volume of fuel. This
fuel. The common reference is to kinematic viscosity. parameter is quoted in the following kg/m3 at 15 °C
Kinematic viscosity is the quotient of the dynamic (59 °F).
viscosity that is divided by the density. The
determination of kinematic viscosity is normally by Perkins recommends a density of 841 kg/m 3 in order
readings from gravity flow viscometers at standard to obtain the correct power output. Lighter fuels are
temperatures. Refer to “ISO 3104” for the test acceptable but these fuels will not produce the rated
method. power.
Sulfur
The level of sulfur is governed by emissions
legislations. Regional regulation, national regulations,
or international regulations can require a fuel with a
specific sulfur limit. The sulfur content of the fuel and
the fuel quality must comply with all existing local
regulations for emissions.
72 SEBU9068
Refill Capacities
Perkins 854 industrial engine have been designed to Recommendation for Biodiesel and Using
operate only with ULSD. By using the test methods
“ASTM D5453, ASTM D2622, or ISO 20846 ISO B20
20884”, the content of sulfur in ULSD fuel must be
below 15 PPM (mg/kg) or 0.0015% mass. Biodiesel is a fuel that can be defined as mono-alkyl
esters of fatty acids. Biodiesel is a fuel that can be
made from various feedstock. The most commonly
NOTICE
available biodiesel in Europe is Rape Methyl Ester
Use of diesel fuel with higher than 15 PPM sulphur (RME). This biodiesel is derived from rapeseed oil.
limit in these engines will harm or permanently dam- Soy Methyl Ester (SME) is the most common
age emissions control systems and/or shorten their biodiesel in the United States. This biodiesel is
service interval. derived from soybean oil. Soybean oil or rapeseed oil
are the primary feedstocks. These fuels are together
known as Fatty Acid Methyl Esters (FAME).
Lubricity Raw pressed vegetable oils are NOT acceptable for
use as a fuel in any concentration in compression
Lubricity is the capability of the fuel to prevent pump engines. Without esterification, these oils solidify in
wear. The fluids lubricity describes the ability of the the crankcase and the fuel tank. These fuels may not
fluid to reduce the friction between surfaces that are be compatible with many of the elastomers that are
under load. This ability reduces the damage that is used in engines that are manufactured today. In
caused by friction. Fuel injection systems rely on the original forms, these oils are not suitable for use as a
lubricating properties of the fuel. Until fuel sulfur limits fuel in compression engines. Alternate base stocks
were mandated, the fuels lubricity was generally for biodiesel may include animal tallow, waste
believed to be a function of fuel viscosity. cooking oils, or various other feedstocks. In order to
The lubricity has particular significance to the current use any of the products that are listed as fuel, the oil
ultra low sulfur fuel, and low aromatic fossil fuels. must be esterified.
These fuels are made in order to meet stringent Fuel made of 100 percent FAME is generally referred
exhaust emissions. to as B100 biodiesel or neat biodiesel.
The lubricity of these fuels must not exceed wear scar Biodiesel can be blended with distillate diesel fuel.
diameter of 0.52 mm (0.0205 inch). The fuel lubricity The blends can be used as fuel. The most commonly
test must be performed on an HFRR, operated at available biodiesel blends are B5, which is 5 percent
60 °C (140 °F). Refer to “ISO 12156-1”. biodiesel and 95 percent distillate diesel fuel. B20,
which is 20 percent biodiesel and 80 percent distillate
NOTICE diesel fuel.
The fuels system has been qualified with fuel having
lubricity up to 0.52 mm (0.0205 inch) wear scar diam- Note: The percentages given are volume-based.
eter as tested by “ISO 12156-1”. Fuel with higher
wear scar diameter than 0.52 mm (0.0205 inch) will The U.S. distillate diesel fuel specification “ASTM
lead to reduced service life and premature failure of D975-09a” includes up to B5 (5 percent) biodiesel.
the fuel system. European distillate diesel fuel specification EN590:
2010 includes up B7 (7 percent) biodiesel.
Fuel additives can enhance the lubricity of a fuel. Note: Engines that are manufactured by Perkins are
Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier certified by use of the prescribed Environmental
can make recommendations for additives to use, and Protection Agency (EPA) and European Certification
for the proper level of treatment. fuels. Perkins does not certify engines on any other
fuel. The user of the engine has the responsibility of
Distillation using the correct fuel that is recommended by the
manufacturer and allowed by the EPA and other
Distillation is an indication of the mixture of different appropriate regulatory agencies.
hydrocarbons in the fuel. A high ratio of light weight
hydrocarbons can affect the characteristics of Specification Requirements
combustion.
The neat biodiesel must conform to the latest
“EN14214 or ASTM D6751” (in the USA). The
biodiesel can only be blended in mixture of up to 20%
by volume in acceptable mineral diesel fuel meeting
latest edition of “EN590 or ASTM D975 S15”
designation.
SEBU9068 73
Refill Capacities
In United States Biodiesel blends of B6 to B20 must Biodiesel and biodiesel blends are known to cause an
meet the requirements listed in the latest edition of increase in fuel system deposits, most significant of
“ASTM D7467” (B6 to B20) and must be of an API which are deposits within the fuel injector. These
gravity of 30-45. deposits can cause a loss in power due to restricted
or modified fuel injection or cause other functional
In North America biodiesel and biodiesel blends must issues associated with these deposits.
be purchased from the BQ-9000 accredited
producers and BQ-9000 certified distributors. Note: Perkins T400012 Fuel Cleaner is most
effective in cleaning and preventing the formation of
In other areas of the world, the use of biodiesel that is deposits. Perkins Diesel Fuel Conditioner helps to
BQ-9000 accredited and certified, or that is
accredited and certified by a comparable biodiesel limit deposit issues by improving the stability of
quality body to meet similar biodiesel quality biodiesel and biodiesel blends. For more information
standards is required. refer to “Perkins Diesel Fuel System Cleaner”.
Biodiesel fuel contains metal contaminants (sodium,
Engine Service Requirements potassium, calcium, and/or magnesium) that form ash
products upon combustion in the diesel engine. The
Aggressive properties of biodiesel fuel may cause ash can have an impact on the life and performance
debris in the fuel tank and fuel lines. The aggressive of aftertreatment emissions control devices.
properties of biodiesel will clean the fuel tank and fuel
lines. This cleaning of the fuel system can
prematurely block of the fuel filters. Perkins General Requirements
recommend that after the initial usage of B20
biodiesel blended fuel the fuel filters must be replaced Biodiesel has poor oxidation stability, which can result
at 50 hours. in long-term problems in the storage of biodiesel.
Biodiesel fuel should be used within 6 months of
Glycerides present in biodiesel fuel will also cause manufacture. Equipment should not be stored with
fuel filters to become blocked more quickly. Therefore the B20 biodiesel blends in the fuel system for longer
the regular service interval should be reduced to 250 than 3 months.
hours.
Due to poor oxidation stability and other potential
When biodiesel fuel is used, crank case oil and issues, it is strongly recommended that engines with
aftertreatment systems may be influenced. This limited operational time either not use B20 biodiesel
influence is due to the chemical composition and blends or, while accepting some risk, limit biodiesel
characteristics of biodiesel fuel, such as density and blend to a maximum of B5. Examples of applications
volatility, and to chemical contaminants that can be that should limit the use of biodiesel are the following:
present in this fuel, such as alkali and alkaline metals Standby Generator sets and certain emergency
(sodium, potassium, calcium, and magnesium). vehicles.
• Crankcase oil fuel dilution can be higher when Perkins strongly recommended that seasonally
biodiesel or biodiesel blends are used. This operated engines have the fuel systems, including
increased level of fuel dilution when using fuel tanks, flashed with conventional diesel fuel
before prolonged shutdown periods. An example of
biodiesel or biodiesel blends is related to the
an application that should seasonally flush the fuel
typically lower volatility of biodiesel. In-cylinder system is a combine harvester.
emissions control strategies utilized in many of the
industrial latest engine designs may lead to a Microbial contamination and growth can cause
higher level of biodiesel concentration in the sump. corrosion in the fuel system and premature plugging
The long-term effect of biodiesel concentration in of the fuel filter. Consult your supplier of fuel for
crankcase oil is currently unknown. assistance in selecting appropriate anti-microbial
additive.
• Perkins recommend the use of oil analysis in
order to check the quality of the engine oil if Water accelerates microbial contamination and
growth. When biodiesel is compared to distillate fuels,
biodiesel fuel is used. Ensure that the level of water is naturally more likely to exist in the biodiesel.
biodiesel in the fuel is noted when the oil sample is It is therefore essential to check frequently and if
taken. necessary, drain the water separator.
Performance Related Issues Materials such as brass, bronze, copper, lead, tin,
and zinc accelerate the oxidation process of the
Due to the lower energy content than the standard biodiesel fuel. The oxidation process can cause
distillate fuel B20 will cause a power loss in order of 2 deposits formation therefore these materials must not
to 4 percent. In addition, over time the power may be used for fuel tanks and fuel lines.
deteriorate further due to deposits in the fuel injectors.
74 SEBU9068
Refill Capacities
Fuel for Cold Weather Operation Once the fuel cleaner has been added to the fuel, the
deposits within the fuel system are removed after 30
The European standard “EN590” contains climate hours of engine operation. For maximum results,
dependant requirements and a range of options. The continue to use the fuel cleaner for up to 80 hours.
options can be applied differently in each country. Perkins fuel cleaner can be used on an on-going
There are five classes that are given to arctic climates basis with no adverse impact on engine or fuel
and severe winter climates. 0, 1, 2, 3 and 4. system durability.
Fuel that complies with “EN590” CLASS 4 can be Details instruction on the rate of which the fuel
used at temperatures as low as −44 °C (−47.2 °F). cleaner must be use are on the container.
Refer to “EN590” for a detailed discretion of the
physical properties of the fuel. Note: Perkins fuel cleaner is compatible with
existing and U.S. EPA Tier 4 nonroad certified diesel
The diesel fuel “ASTM D975 1-D” used in the United engine emission control catalysts and particulate
States of America may be used in very cold filters. Perkins fuel system cleaner contains less
temperatures that are below −18 °C (−0.4 °F). than 15 ppm of sulfur and is acceptable for use with
ULSD fuel.
Aftermarket Fuel Additives
Supplemental diesel fuel additives are not generally
recommended. This recommendation is due to
potential damage to the fuel system or the engine.
Your fuel supplier or the fuel manufacturer will add the
appropriate supplemental diesel fuel additives.
Perkins recognizes the fact that additives may be
required in some special circumstances.
Note: Some anti-corrosion additives can lead to

injector fouling, this fouling can cause the injector to
operate incorrectly.
Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier
can recommend the appropriate fuel additive and the
correct level of treatment.
Note: For the best results, your fuel supplier should

treat the fuel when additives are required. The treated
fuel must meet the requirements that are stated in
table 21 .
Perkins Diesel Fuel System Cleaner

Perkins T400012 Fuel Cleaner is the only fuel
cleaner that is recommended by Perkins .
If biodiesel or biodiesel blends of fuel are to be used,
Perkins require the use of Perkins fuel cleaner. The
use of the fuel is in order to remove deposits within
the fuel system that is created with the use of
biodiesel. For more information on the use of
biodiesel and biodiesel blends refer to
“Recommendation for Biodiesel and Using B20”.
Perkins fuel cleaner will remove deposits that can
form in the fuel system with the use of biodiesel and
biodiesel blends. These deposits can create a loss of
power and engine performance.
SEBU9068 75
Maintenance Recommendations
System Pressure Release
Maintenance
1. Stop the engine.
Recommendations
2. Wait for 10 minutes.
i03648938
Do not loosen the high pressure fuel lines in order to
remove air from the fuel system.
System Pressure Release
Engine Oil
Coolant System
To relieve pressure from the lubricating system, turn
off the engine.
i05944164
Pressurized system: Hot coolant can cause seri- Welding on Engines with
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve Electronic Controls
the pressure.
The engine can have the ability to auto start. Ensure NOTICE
that the power supply is isolated before any service or Because the strength of the frame may decrease,
repair is performed. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Perkins dealer regarding welding on a
off the engine. Allow the cooling system pressure cap chassis frame or rail.
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure.
Proper welding procedures are necessary in order to
Fuel System avoid damage to the engines ECM, sensors, and
associated components. When possible, remove the
To relieve the pressure from the fuel system, turn off component from the unit and then weld the
the engine. component. If removal of the component is not
possible, the following procedure must be followed
High Pressure Fuel Lines when you weld on a unit equipped with an Electronic
Engine. The following procedure is considered to be
the safest procedure to weld on a component. This
procedure should provide a minimum risk of damage
to electronic components.
penetration and burn hazards. High pressure fuel NOTICE
spray may cause a fire hazard. Failure to follow Do not ground the welder to electrical components
these inspection, maintenance and service in- such as the ECM or sensors. Improper grounding can
structions may cause personal injury or death. cause damage to the drive train bearings, hydraulic
components, electrical components, and other
components.
The high pressure fuel lines are the fuel lines that are
between the high pressure fuel pump and the high Clamp the ground cable from the welder to the com-
pressure fuel manifold and the fuel lines that are ponent that will be welded. Place the clamp as close
between the fuel manifold and cylinder head. These as possible to the weld. This will help reduce the pos-
fuel lines are different from fuel lines on other fuel sibility of damage.
systems.
This is because of the following differences: Note: Perform the welding in areas that are free from
explosive hazards.
• The high pressure fuel lines are constantly
charged with high pressure. 1. Stop the engine. Turn the switched power to the
OFF position.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system. 2. Ensure that the fuel supply to the engine is turned
Before any service or repair is performed on the off.
engine fuel lines, perform the following tasks:
76 SEBU9068
Welding on Engines with Electronic Controls
3. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is provided,
open the switch.
4. Disconnect all electronic components from the

wiring harnesses. Include the following
components:
• Electronic components for the driven equipment
• ECM
• Sensors and control boxes
• Electronically controlled valves
• Relays
• Diesel exhaust fluid pump controller
NOTICE
Do not use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being welded
and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
5. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to the
following components. Bearings, hydraulic
components, electrical components, and ground
straps.
Note: If electrical/electronic components are used as
a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.
6. Protect the wiring harness from welding debris and

spatter.
SEBU9068 77
Severe Service Application
7. Use standard welding practices to weld the Severe Operating Conditions

materials.
• Frequent operation with inlet air which has a
corrosive content
i05977593
• Operation with inlet air which has a combustible

Severe Service Application content
• Operation which is outside of the intended

An engine which operates outside of normal application
conditions is operating in a severe service
application. • Operation with a plugged fuel filter
An engine that operates in a severe service • Extended operation at low idle (more than 20% of
application may need more frequent maintenance hours)
intervals in order to maximize the following
conditions: • Continuous operation at idle or elevated idle
• Reliability • Frequent cold starts at temperatures below 0° C

(32° F)
• Service life
• Frequent cold starts at high altitudes which are
Severe service operation can accelerate component above 1525 m (5000. ft)
wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in • Frequent dry starts (starting after more than 72
order to ensure maximum reliability and retention of hours of shutdown)
full service life.
• Frequent hot shutdowns (shutting down the engine
Due to individual applications, it is not possible to
without the minimum of 2 minutes to 5 minutes of
identify all of the factors which can contribute to
severe service operation. Consult your Perkins cool down time)
distributor for the unique maintenance that is
necessary for the engine. • Operation above the engine rated speed
The operating environment, incorrect operating • Operation below the peak torque speed
procedures, and incorrect maintenance procedures
can be factors which contribute to a severe service • Operation of the engine above a load factor that
application. exceeds the rating of the engine
Severe Environmental Factors • Operation at light loads for extended periods
• Frequent operation in dirty air • Operating with fuel which does not meet the
standards for distillate diesel fuel as stated in this
• Frequent operation at an altitude which is above Operation and Maintenance Manual, “Fluid
1525 m (5000 ft) Recommendations”.
• Frequent operation in ambient temperatures which • Operating with a blend of distillate fuel which
are above 32° C (90° F) contains more than 20 percent biodiesel
• Frequent operation in ambient temperatures which Incorrect Maintenance Procedures

are below 0° C (32° F)
• Extending the maintenance intervals
• Failure to use recommended fuel, lubricants, and

coolant/antifreeze
78 SEBU9068
Maintenance Interval Schedule
i05835964 “Engine Air Cleaner Element (Single Element) -

Inspect/Replace”......................................................93
Maintenance Interval Schedule
“Engine Oil and Filter - Change”..............................97
When Required “Fuel System Primary Filter (Water Separator)
Element - Replace”............................................... 101
“Fuel System Secondary Filter - Replace” ........... 103
“Battery - Replace”...................................................80
“Radiator - Clean” ................................................. 106
“Battery or Battery Cable - Disconnect”...................81
“DEF Filler Screen - Clean” .....................................87 Every 1000 Service Hours
“Diesel Exhaust Fluid - Fill”......................................88 “Water Pump - Inspect”......................................... 109
“Diesel Exhaust Fluid Tank - Flush”.........................90 Every 1500 Service Hours

“Engine - Clean”.......................................................90 “Engine Crankcase Breather Element - Replace” ...95
“Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace” ...........................................91 Every 2000 Service Hours
“Engine Air Cleaner Element (Single Element) - “Aftercooler Core - Inspect” .....................................79
Inspect/Replace”......................................................93
“Engine Mounts - Inspect” .......................................96
“Engine Oil Sample - Obtain”...................................97
“Starting Motor - Inspect” ...................................... 107
“Fuel System - Prime”........................................... 100
“Turbocharger - Inspect” .......................................107
Daily Every 3000 Service Hours
“Coolant Level - Check”...........................................86
“Alternator - Inspect” ................................................79
“Driven Equipment - Check” ....................................90
“Alternator and Fan Belts - Replace” .......................79
“Engine Air Cleaner Service Indicator - Inspect” .....94
“Diesel Exhaust Fluid Filter - Clean/Replace” .........89
“Engine Air Precleaner - Check/Clean” ...................95
Every 3000 Service Hours or 2
“Engine Oil Level - Check”.......................................96
Years
“Fuel System Primary Filter/Water Separator -
“Coolant (DEAC) - Change”.....................................82
Drain” .................................................................... 103
“Walk-Around Inspection”..................................... 108 Every 4000 Service Hours
Every Week “Aftercooler Core - Clean/Test”................................79
“Hoses and Clamps - Inspect/Replace”................ 105 Every 6000 Service Hours or 3

Years
Every 50 Service Hours or Weekly
“Coolant Extender (ELC) - Add” ..............................86
“Fuel Tank Water and Sediment - Drain” .............. 105
Every 10 000 Service Hours
Every 500 Service Hours
“DEF Manifold Filters - Replace” .............................88
“Fan Clearance - Check” .........................................99
Every 12 000 Service Hours or 6
Every 500 Service Hours or 1 Year Years
“Battery Electrolyte Level - Check” ..........................81 “Coolant (ELC) - Change”........................................84
“Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace” ...........................................91 Commissioning
“Fan Clearance - Check” .........................................99
SEBU9068 79
Aftercooler Core - Clean/Test
i01807350 i02322311
Aftercooler Core - Clean/Test Alternator - Inspect

(Air-To-Air Aftercooler)
Perkins recommends a scheduled inspection of the
alternator. Inspect the alternator for loose
The air-to-air aftercooler is OEM installed in many connections and correct battery charging. Check the
applications. Please refer to the OEM specifications ammeter (if equipped) during engine operation in
for information that is related to the aftercooler. order to ensure correct battery performance and/or
correct performance of the electrical system. Make
i02322295 repairs, as required.
Aftercooler Core - Inspect Check the alternator and the battery charger for
correct operation. If the batteries are correctly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
Note: Adjust the frequency of cleaning according to batteries should be kept warm because temperature
the effects of the operating environment. affects the cranking power. If the battery is too cold,
the battery will not crank the engine. When the engine
Inspect the aftercooler for these items: damaged fins, is not run for long periods of time or if the engine is
corrosion, dirt, grease, insects, leaves, oil and other run for short periods, the batteries may not fully
debris. Clean the aftercooler, if necessary. charge. A battery with a low charge will freeze more
easily than a battery with a full charge.
For air-to-air aftercoolers, use the same methods that
are used for cleaning radiators.
i04407613
Alternator and Fan Belts -

Personal injury can result from air pressure. Replace
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing. 1. Remove the guard that covers the alternator. Refer
to the Original Equipment Manufacture (OEM) for
Maximum air pressure at the nozzle must be less the correct procedure.
than 205 kPa (30 psi) for cleaning purposes.
After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine. Use
a light bulb behind the core in order to inspect the
core for cleanliness. Repeat the cleaning, if
necessary.
Inspect the fins for damage. Bent fins may be opened
with a “comb”.
Note: If parts of the aftercooler system are repaired
or replaced, a leak test is highly recommended.
Inspect these items for good condition: Welds,
mounting brackets, air lines, connections, clamps and
seals. Make repairs, if necessary.
80 SEBU9068
Battery - Replace
5. Install the new belt, use belt configuration (A).

Visually check that the belt is correctly aligned.
6. Turn the screw (2) clockwise in order to tension the

belt. Ensure that the link adjuster (7) is at the
maximum extension, refer to illustration 36 .
7. Tighten bolt (5), nut, and bolt (6) and tighten nut
and bolt (1). Tighten these nuts and bolts to
50 N·m (37 lb ft).
8. Rotate bolt (2) counter clockwise two complete

revolutions and tighten nut (3) to 30 N·m (22 lb ft).
9. Install the guard, refer to OEM for more

information.
i03559623
Battery - Replace
2. Loosen bolt (5) and loosen nut and bolt 6. Also,

loosen nut and bolt (1).
Batteries give off combustible gases which can
3. Loosen nut (3) and turn screw (2) counter explode. A spark can cause the combustible
clockwise. Turn the screw (2) in order to give gases to ignite. This can result in severe personal
clearance to remove the belt (4). injury or death.
Ensure proper ventilation for batteries that are in
4. Remove belt (4) and visually check all pulleys that an enclosure. Follow the proper procedures in or-
the belt operates. Ensure that all pulleys are clean der to help prevent electrical arcs and/or sparks
and free from damage. Ensure that the pulleys near batteries. Do not smoke when batteries are
serviced.
rotate freely. Replace any component that is
damaged.
The battery cables or the batteries should not be

removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Switch the engine to the OFF position. Remove all

electrical loads.
2. Turn off any battery chargers. Disconnect any
battery chargers.
3. Ensure that the battery disconnect switch is in the

OFF position.
4. Disconnect the NEGATIVE “-” cable from the

NEGATIVE “-” battery terminal.
(A) Belt configuration
SEBU9068 81
Battery Electrolyte Level - Check
5. Disconnect the POSITIVE “+” cable from the • Use a solution of 0.1 kg (0.2 lb) baking soda
POSITIVE “+” battery terminal. and 1 L (1 qt) of clean water.
• Use a solution of ammonium hydroxide.

Note: Always recycle a battery. Never discard a
battery. Dispose of used batteries to an appropriate Thoroughly rinse the battery case with clean water.
recycling facility.
6. Remove the used battery. i02323088
7. Install the new battery. Battery or Battery Cable -

Note: Before the cables are connected, ensure that Disconnect
the battery disconnect switch is in the OFF position.
8. Connect the POSITIVE “+” cable to the POSITIVE
“+” battery terminal.
9. Connect the NEGATIVE “-” cable to the The battery cables or the batteries should not be
NEGATIVE “-” battery terminal. removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
10. Turn the battery disconnect switch to the ON ing is attempted.
position.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
i02747977
resulting in personal injury.
Battery Electrolyte Level -
1. Turn the start switch to the OFF position. Turn the
Check ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
When the engine is not run for long periods of time or 2. Disconnect the negative battery terminal. Ensure
when the engine is run for short periods, the batteries that the cable cannot contact the terminal. When
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries four 12 volt batteries are involved, two negative
are correctly charged, the ammeter reading should be connection must be disconnected.
very near zero, when the engine is in operation.
3. Remove the positive connection.
4. Clean all disconnected connection and battery

terminals.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a 5. Use a fine grade of sandpaper to clean the
face shield and protective clothing when working terminals and the cable clamps. Clean the items
on or near batteries. until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal of
1. Remove the filler caps. Maintain the electrolyte material can cause the clamps to not fit correctly.
level to the “FULL” mark on the battery. Coat the clamps and the terminals with a suitable
silicone lubricant or petroleum jelly.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean 6. Tape the cable connections in order to help prevent
water that is low in minerals. Do not use artificially accidental starting.
softened water.
7. Proceed with necessary system repairs.
2. Check the condition of the electrolyte with a
suitable battery tester. 8. In order to connect the battery, connect the positive
connection before the negative connector.
3. Install the caps.
4. Keep the batteries clean.

Clean the battery case with one of the following
cleaning solutions:
82 SEBU9068
Coolant (DEAC) - Change
i05859216 1. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in order
Coolant (DEAC) - Change to relieve any pressure. Remove the cooling
system filler cap.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Dispose of all fluids according to Local regulations
and mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Clean the cooling system and flush the cooling

system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently. Typical example
• Foaming of the coolant is observed.
2. Remove the drain plug (1) on the engine. Also,
• The oil has entered the cooling system and the open drain cock or remove the drain plug on the
coolant is contaminated. radiator.
• The fuel has entered the cooling system and the Allow the coolant to drain.
coolant is contaminated.
Note: When the cooling system is cleaned, only

clean water is needed.
NOTICE
When any servicing or repair of the engine cooling
system is performed, the procedure must be per-
formed with the engine on level ground. This action
will allow you to check accurately the coolant level.
This action will also help in avoiding the risk of intro-
ducing an air lock into the coolant system.
Drain

pressure.
SEBU9068 83
Coolant (DEAC) - Change
5. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in order
to relieve any pressure. Remove the cooling
system filler cap. Remove the drain plug on the
engine. Open the drain cock or remove the drain
plug on the radiator. Allow the water to drain. Flush
the cooling system with clean water.
Fill
1. Install the drain plug on the engine. Close the drain
cock or install the drain plug on the radiator.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute, in order to avoid air locks.
Cooling system air locks may result in engine
damage.
Illustration 38 g03732615 2. Fill the cooling system with Commercial Heavy-

Duty Coolant. Add Supplemental Coolant Additive
3. For radiators installed by the engine manufacturer, to the coolant. For the correct amount, refer to the
remove the drain plug (2) from radiator (3) and Operation and Maintenance Manual, “Fluid
allow coolant to drain. After the system has been Recommendations” topic (Maintenance Section)
flushed, install the drain plug to a torque of 6 N·m for more information on cooling system
(53 lb in). specifications. Do not install the cooling system
filler cap.
NOTICE
Dispose of used engine coolant or recycle. Various 3. Start and run the engine at low idle. Increase the
methods have been proposed to reclaim used coolant engine rpm to high idle. Operate the engine in
for reuse in engine cooling systems. The full distilla- order to open the engine thermostat. This
tion procedure is the only method acceptable by Per- operation will allow any air in the system to be
kins to reclaim the coolant. purged. Decrease the engine speed to low idle.
Stop the engine.
For information regarding the disposal and the
recycling of used coolant, consult your Perkins 4. Maintain the coolant level at the maximum mark
distributor. that is correct for your application.
Flush
1. Flush the cooling system with clean water in order
to remove any debris.

3. Fill the cooling system with clean water. Install the

cooling system filler cap.
4. Start and run the engine at low idle until the

temperature reaches 49 to 66 °C (120 to 150 °F).
84 SEBU9068
Coolant (ELC) - Change
NOTICE
component life.
Clean the cooling system and flush the cooling

system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.

• Foaming of the coolant is observed.
• The oil has entered the cooling system and the

• The fuel has entered the cooling system and the
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and
Illustration 39 g02590196 replaced.
Filler cap
Note: Inspect the water pump and the water
5. Clean the cooling system filler cap and inspect the temperature regulator after the cooling system has
gasket. If the gasket is damaged, discard the old been drained. This inspection can be a good
opportunity to replace the water pump, the water
filler cap and install a new filler cap. If the gasket is
temperature regulator, and the hoses, if necessary.
not damaged, use a suitable pressurizing pump in
order to pressure test the filler cap. The correct NOTICE
pressure is stamped on the face of the filler cap. If When any servicing or repair of the engine cooling
the filler cap does not retain the correct pressure, system is performed, the procedure must be per-
install a new filler cap. formed with the engine on level ground. Level ground
6. Start the engine. Inspect the cooling system for This check will also help in avoiding the risk of intro-
leaks and for correct operating temperature. ducing an air lock into the coolant system.
i05944034
Drain

NOTICE ous burns. To open the cooling system filler cap,
Care must be taken to ensure that fluids are con- stop the engine and wait until the cooling system
tained during performance of inspection, mainte- components are cool. Loosen the cooling system
nance, testing, adjusting and repair of the product. Be pressure cap slowly in order to relieve the
prepared to collect the fluid with suitable containers pressure.
any component containing fluids.
1. Stop the engine and allow the engine to cool.
Dispose of all fluids according to Local regulations Loosen the cooling system filler cap slowly in order
and mandates. to relieve any pressure. Remove the cooling
system filler cap.
SEBU9068 85
NOTICE
Dispose of used engine coolant or recycle. Various
methods have been proposed to reclaim used coolant
for reuse in engine cooling systems. The full distilla-
tion procedure is the only method acceptable by Per-
kins to reclaim the coolant.
For information regarding the disposal and the

recycling of used coolant, consult your Perkins
distributor.
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
2. Install the drain plug in the engine. Close the drain

3. Fill the cooling system with clean water. Install the

Typical example 4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
2. Remove the drain plug (1) on the engine. Also,
open the drain cock or remove the drain plug on 5. Stop the engine and allow the engine to cool.
the radiator. Loosen the cooling system filler cap slowly in order
Allow the coolant to drain. system filler cap. Remove the drain plug on the
engine. Open the drain cock or remove the drain
plug on the radiator. Allow the water to drain. Flush
the cooling system with clean water.
Fill
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute, in order to avoid air locks.
Cooling system air locks may result in engine
damage.
2. Fill the cooling system with Extended Life Coolant

(ELC). Refer to the Operation and Maintenance
Manual, “Fluid Recommendations” topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
3. For radiators installed by the engine manufacturer, 3. Start and run the engine at low idle. Increase the
remove the drain plug (2) from radiator (3) and engine rpm to high idle. Operate the engine in
allow coolant to drain. After the system has been order to open the engine thermostat. This
flushed, install the drain plug to a torque of 6 N·m procedure will allow any air in the system to be
(53 lb in). purged. Decrease the engine speed to low idle.
Stop the engine.
86 SEBU9068
Coolant Extender (ELC) - Add
i05979531
4. Maintain the coolant level at the maximum mark
that is correct for your application. Coolant Level - Check

pressure.
Note: The Diesel Exhaust Fluid (DEF) tank requires

coolant flow around the tank. The Coolant Diverter
Valve (CDV) will turn the flow on or off. If the coolant
system has been filled with the CDV in the closed
position, coolant level will drop because of the
opening of the CDV.
Engine with Radiator Installed by

the Engine Manufacturer
NOTICE
Filler cap When any servicing or repair of the engine cooling
system is performed, the procedure must be per-
5. Clean the cooling system filler cap and inspect the formed with the engine on level ground. Level ground
gasket. If the gasket is damaged, discard the old will allow you to check accurately the coolant level.
filler cap and install a new filler cap. If the gasket is This checking will also help in avoiding the risk of in-
not damaged, use a suitable pressurizing pump in troducing an air lock into the coolant system.
order to pressure test the filler cap. The correct
pressure is stamped on the face of the filler cap. If
1. Check the coolant level when the engine is
the filler cap does not retain the correct pressure,
stopped and cool.
install a new filler cap.
2. Loosen filler cap slowly in order to relieve any
6. Start the engine. Inspect the cooling system for
pressure. Remove the filler cap.
leaks and for correct operating temperature.
i05197396
Coolant Extender (ELC) - Add
In order for Perkins ELC to achieve 12000 hours an

extender must be added at 6000 hours. For a suitable
extender, contact your Perkins dealer or Perkins
distributor.
SEBU9068 87
DEF Filler Screen - Clean
3. Check the pressure cap for damage, replace if

necessary. Install the pressure cap. Inspect the
cooling system for leaks.
i05921440
DEF Filler Screen - Clean
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
3. Maintain the coolant level 25 mm (1 inch) below

the filler neck (1).
4. Check the pressure cap for damage, replace if

necessary. Install the pressure cap. Inspect the
cooling system for leaks.
Engine with Radiator Installed by

OEM
Note: The cooling system may not have been
provided by Perkins . The procedure that follows is
for typical cooling systems. Refer to the OEM
information for the correct procedures.
Check the coolant level when the engine is stopped
and cool.
NOTICE
When any servicing or repair of the engine cooling Illustration 44 g03725939
system is performed, the procedure must be per- Typical example
formed with the engine on level ground. Level ground
This checking will also help in avoiding the risk of in- 1. Ensure that the area around cap on the Diesel
troducing an air lock into the coolant system. Exhaust Fluid (DEF) tank is clean. Remove cap
(1).
1. Loosen filler cap slowly in order to relieve any 2. Using a suitable tool, press the tabs (2) in order to
pressure. Remove the filler cap. release the tabs. With the tabs released remove
the filter screen (3) from DEF tank neck adapter
2. Maintain the coolant level at the maximum mark
(4).
that is correct for your application. If the engine is
equipped with a sight glass, maintain the coolant
level to the correct level in the sight glass.
88 SEBU9068
DEF Manifold Filters - Replace
3. The filter screen can be cleaned in clean water and i05771029

dried using compressed air. Refer to this Operation
and Maintenance Manual, “General Hazard Diesel Exhaust Fluid - Fill
Information” for information on using compressed
air.
4. If the filter screen cannot be cleaned or the filter
screen is damaged, then the filter screen must be
replaced.
5. Install filter screen (3) into DEF tank neck adapter

(4). Press filter screen into neck adapter and
ensure that tabs (2) are located correctly. Install
cap (1).
i05921489
DEF Manifold Filters - Replace
Typical example
Ensure that the correct specification Diesel Exhaust

Fluid (DEF) is used. Ensure the cleanliness of the
DEF, refer to this Operation and Maintenance
Manual, “Fluid Recommendations” for more
information.
Care should be taken when dispensing DEF. Spills
should be cleaned immediately. All surfaces should
be wiped clean and rinsed with water.
DEF that has been split will crystallize when the water
within the liquid evaporates. Split DEF will attack
paint and metal. If DEF is split, wash the area with
water.
Caution should be used when dispensing DEF near
Typical example an engine that has recently been running. Spilling
DEF onto hot components may cause the release of
Replace the manifold filter (1). Refer to Disassembly ammonia vapors. Do not breathe ammonia vapors.
and Assembly, “Manifold (DEF Heater) - Remove and Do not clean up any spills with bleach.
Install” for more information.
Ensure that the DEF tank is full before starting work.
1. Before filling the DEF tank, ensure that the DEF

lines have been purged. Purging of the DEF lines
will take place, after the engine has stopped. Only
after purging the DEF lines should the DEF tank be
filled. For more information on the time taken for
purging the DEF lines, refer to this Operation and
Maintenance Manual, “Battery Disconnect Switch”.
SEBU9068 89
Diesel Exhaust Fluid Filter - Clean/Replace
2. Ensure that the DEF cap (1) and the surrounding

area is clean and free from dirt. Ensure that all
equipment use in filling the tank is clean and free
from dirt.
3. Remove the DEF cap from the tank.
4. Fill the tank with the required amount of DEF.

Ensure that dirt is not introduced into the tank
during filling. Do not over fill the tank. The DEF will
require room for expansion.
Note: Always fill the DEF tank on level ground. Cold

weather can affect DEF, refer to this Operation and
Maintenance Manual, “Diesel Exhaust Fluid in cold
Weather” for more information.
5. The opening on the DEF tank (2) is a special
diameter. Ensure that the correct nozzle is used
when filling the DEF tank.
6. Install the DEF cap. Check visually the DEF tank

for leakage.
i05940598
Diesel Exhaust Fluid Filter -

Clean/Replace Illustration 47 g03731253
Typical example
1. Ensure that the area around the Diesel Exhaust

Fluid (DEF) filter is clean and free from dirt.
2. Use a 27mm Bi-Hex socket in order to remove cap

(3). Remove the expansion device (2).
3. Using tool supplied, insert tool into position (A).

Remove DEF filter element (4) from main body (1).
Note: Check the orientation of the new DEF filter

element before installing.
4. Install new DEF filter element into main body .
Install expansion device into filter element . Install
cap and tighten cap to 20 N·m (14 lb ft).
90 SEBU9068
Diesel Exhaust Fluid Tank - Flush
i06080114
2. If necessary, install the DEF filler screen. For more
Diesel Exhaust Fluid Tank - information, refer to this Operation and
Maintenance Manual, “DEF Filler Screen - Clean”.
Flush
3. Install the drain plug (4). Tighten the drain plug to a
torque of 6 N·m (53 lb in). Remove the vessel
used for draining. Dispose of the drain fluid in
accordance with local regulation.
Note: At key on after the tank has been drained

completely the DEF level gauge will show the last
known DEF level. The DEF level gauge will start
working accurately as the tank is being filled with
DEF.
4. Refill the DEF tank (3). Refer to this Operation and
Maintenance Manual, “Diesel Exhaust Fluid - Fill”
for more information.
If the DEF tank has been fill with another fluid other
than DEF, then contact your Perkins dealer or your
Perkins distributor .
i02151646
Driven Equipment - Check

Refer to the OEM specifications for more information
Typical example on the following maintenance recommendations for
the driven equipment:
If contamination of the Diesel Exhaust Fluid (DEF) is
suspected, the DEF tank (3) will need to be drained • Inspection
and the DEF tank flushed.
• Adjustment
1. Ensure that the purging of the DEF system has
been completed. • Lubrication
• Other maintenance recommendations

Note: Ensure that the vessel that will be used is large
enough to collect the fluid to be drained. Perform any maintenance for the driven equipment
2. Position the vessel below the drain plug (4). which is recommended by the OEM.
Remove the filler cap (1) Remove the drain plug
and allow the fluid to drain. i03991933
3. Remove the Manifold (DEF Heater) (2). Refer to Engine - Clean

Disassembly and Assembly, “Manifold (DEF
Heater)-Remove and Install” after draining the
fluid.
4. If necessary, remove the DEF filler screen. For
more information, refer to this Operation and Personal injury or death can result from high
Maintenance Manual, “DEF Filler Screen - Clean”. voltage.
The DEF tank must be flushed after draining. Flush Moisture can create paths of electrical
the tank with deionized water Ensure that all the conductivity.
flushing agents have been drained.
Make sure that the electrical system is OFF. Lock
1. Install the Manifold (DEF Heater) (2). Refer to out the starting controls and tag the controls “ DO
Disassembly and Assembly, “Manifold (DEF NOT OPERATE”” .
Heater)-Remove and Install”.
SEBU9068 91
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
NOTICE
Servicing the Air Cleaner Elements
Accumulated grease and oil on an engine is a fire Note: The air filter system may not have been
hazard. Keep the engine clean. Remove debris and provided by Perkins . The procedure that follows is
fluid spills whenever a significant quantity accumu- for a typical air filter system. Refer to the OEM
lates on the engine. information for the correct procedure.
If the air cleaner element becomes plugged, the air
Periodic cleaning of the engine is recommended. can split the material of the air cleaner element.
Steam cleaning the engine will remove accumulated Unfiltered air will drastically accelerate internal engine
oil and grease. A clean engine provides the following wear. Refer to the OEM information for the correct air
benefits: cleaner elements for your application.
• Easy detection of fluid leaks • Check the precleaner (if equipped) and the dust
bowl daily for accumulation of dirt and debris.
• Maximum heat transfer characteristics Remove any dirt and debris, as needed.
• Ease of maintenance • Operating in dirty conditions may require more
Note: Caution must be used in order to prevent frequent service of the air cleaner element.
electrical components from being damaged by • The air cleaner element should be replaced at
excessive water when the engine is cleaned. least one time per year. This replacement should
Pressure washers and steam cleaners should not be be performed regardless of the number of
directed at any electrical connectors or the junction of cleanings.
cables into the rear of the connectors. Avoid electrical
components such as the alternator, the starter, and Replace the dirty air cleaner elements with clean air
the ECM. Protect the fuel injection pump from fluids in cleaner elements. Before installation, the air cleaner
order to wash the engine. elements should be thoroughly checked for tears and/
or holes in the filter material. Inspect the gasket or the
Aftertreatment seal of the air cleaner element for damage. Maintain a
supply of suitable air cleaner elements for
During the engine cleaning process, ensure that replacement purposes.
water or cleaning fluids cannot enter the
aftertreatment system. If cleaning fluids enters the Dual Element Air Cleaners
aftertreatment system, damage could occur.
The dual element air cleaner contains a primary air
i05207494 cleaner element and a secondary air cleaner
element.
Engine Air Cleaner Element The primary air cleaner element can be used up to six
times if the element is properly cleaned and properly
(Dual Element) - Inspect/Clean/ inspected. The primary air cleaner element should be
Replace replaced at least one time per year. This replacement
should be performed regardless of the number of
cleanings.
NOTICE The secondary air cleaner element is not serviceable.

Refer to the OEM information for instructions in order
Never run the engine without an air cleaner element to replace the secondary air cleaner element.
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with When the engine is operating in environments that
damaged pleats, gaskets or seals. Dirt entering the are dusty or dirty, air cleaner elements may require
engine causes premature wear and damage to en- more frequent replacement.
gine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
92 SEBU9068
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/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) pressur-
ized air or vacuum cleaning to clean the primary air
cleaner element.
Take extreme care in order to avoid damage to the air
cleaner elements.
Do not use air cleaner elements that have damaged
pleats, gaskets, or seals.
Illustration 49 g00736431 Refer to the OEM information in order to determine

the number of times that the primary air cleaner
(1) Cover element can be cleaned. Do not clean the primary air
(2) Primary air cleaner element
(3) Secondary air cleaner element
filter element more than three times. The primary air
(4) Air inlet cleaner element must be replaced at least one time
per year.
1. Remove the cover. Remove the primary air cleaner Cleaning the air filter element will not extend the life
element. of the air filter element.
2. The secondary air cleaner element should be Visually inspect the primary air cleaner element
removed and discarded for every three cleanings before cleaning. Inspect air cleaner elements for
damage to the pleats, the seals, the gaskets, and the
of the primary air cleaner element. outer cover. Discard any damaged air cleaner
element.
Note: Refer to “Cleaning the Primary Air Cleaner
Elements”. Two methods may be used in order to clean the
primary air cleaner element:
3. Cover the air inlet with tape in order to keep out
dirt. • pressurized air
4. Clean the inside of the air cleaner cover and body • Vacuum cleaning
with a clean, dry cloth.
Pressurized Air
5. Remove the tape from the air inlet. Install the
secondary air cleaner element. Install a primary air
cleaner element that is new or cleaned.
6. Install the air cleaner cover. Personal injury can result from air pressure.
7. Reset the air cleaner service indicator. Personal injury can result without following prop-
Cleaning the Primary Air Cleaner protective face shield and protective clothing.
Elements Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Refer to the OEM information in order to determine
the number of times that the primary filter element
can be cleaned. When the primary air cleaner Pressurized air can be used to clean primary air
element is cleaned, check for rips or tears in the filter cleaner elements that have not been cleaned more
material. The primary air cleaner element should be than three times. Use filtered, dry air with a maximum
replaced at least one time per year. This replacement pressure of 207 kPa (30 psi). Pressurized air will not
should be performed regardless of the number of remove deposits of carbon and oil.
cleanings.
SEBU9068 93
Engine Air Cleaner Element (Single Element) - Inspect/Replace
Inspecting the Primary Air Cleaner

Elements
Note: When the primary air cleaner elements are

cleaned, always begin with the clean side (inside) in
order to force dirt particles toward the dirty side
(outside). Inspect the clean, dry primary air cleaner element.
Use a 60 W blue light in a dark room or in a similar
Aim the air hose so that air flows along the length of
facility. Place the blue light in the primary air cleaner
the filter. Follow the direction of the paper pleats in
order to prevent damage to the pleats. Do not aim the element. Rotate the primary air cleaner element.
air directly at the face of the paper pleats. Inspect the primary air cleaner element for tears and/
or holes. Inspect the primary air cleaner element for
Note: Refer to “Inspecting the Primary Air Cleaner light that may show through the filter material. If it is
necessary in order to confirm the result, compare the
Elements”.
primary air cleaner element to a new primary air
cleaner element that has the same part number.
Vacuum Cleaning
Do not use a primary air cleaner element that has any
Vacuum cleaning is a good method for removing tears and/or holes in the filter material. Do not use a
accumulated dirt from the dirty side (outside) of a primary air cleaner element with damaged pleats,
primary air cleaner element. Vacuum cleaning is gaskets, or seals. Discard damaged primary air
especially useful for cleaning primary air cleaner cleaner elements.
elements which require daily cleaning because of a
dry, dusty environment. i01432811
Cleaning from the clean side (inside) with pressurized Engine Air Cleaner Element
air is recommended prior to vacuum cleaning the dirty
side (outside) of a primary air cleaner element. (Single Element) - Inspect/
Note: Refer to “Inspecting the Primary Air Cleaner Replace
Elements”.
Perform the Operation and Maintenance Manual,

“Engine Air Cleaner Service Indicator-Inspect”
procedure and perform the Operation and
Maintenance Manual, “Engine Air Precleaner Check/
Clean” procedure (if equipped) before performing the
following procedure.
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to en-
gine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
94 SEBU9068
Engine Air Cleaner Service Indicator - Inspect
Some engines are equipped with a differential gauge

NOTICE for inlet air pressure. The differential gauge for inlet
Never service the air cleaner element with the engine air pressure displays the difference in the pressure
running since this will allow dirt to enter the engine. that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner element or in a remote location.
(1) Air cleaner cover
(2) Air filter element
(3) Air inlet
1. Remove air cleaner cover (1) and remove air filter

element (2). Illustration 53 g00103777
2. Cover air inlet (3) with tape or a clean cloth so that Typical service indicator
debris cannot enter the air inlet.
Observe the service indicator. The air cleaner
3. Clean the inside of air cleaner cover (1). Clean the element should be cleaned or the air cleaner element
should be replaced when one of the following
body that holds the air cleaner element. conditions occur:
4. Inspect the replacement element for the following • The yellow diaphragm enters the red zone.
items:damage, dirt and debris.
• The red piston locks in the visible position.
5. Remove the seal from the opening of the air inlet.
Test the Service Indicator
6. Install a clean, undamaged air filter element (2).
Service indicators are important instruments.
7. Install air cleaner cover (1).
• Check for ease of resetting. The service indicator
8. Reset the air cleaner service indicator. should reset in less than three pushes.
• Check the movement of the yellow core when the
i02335405 engine is accelerated to the engine rated speed.
The yellow core should latch at the greatest
Engine Air Cleaner Service vacuum that is attained.
Indicator - Inspect If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
Some engines may be equipped with a different service indicator will not reset, the hole for the service
service indicator. indicator may be restricted.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
SEBU9068 95
Engine Air Precleaner - Check/Clean
i05967804 The crankcase breather is a very important

component in order to keep your engine emissions
Engine Air Precleaner - Check/ compliant.
Clean • The filter element within the crankcase breather

must be serviced at the prescribed service interval.
(If Equipped)
• The correct filter element must be installed before
the engine is operated.
• The installation of the filter element is very
important.
• The quality of the filter element that is installed is

very important.
• The filter element protects the engine from

excessive quantities of oil from entering the
induction system. The filter element also protects
the engine aftertreatment system.
Note: Excessive quantities of oil that enter the

induction system of the engine can rapidly increase
the engine speed without control.
Remove the Breather Element
Typical example
(1) Wing nut 1. Remove the guard that covers the engine breather,
(2) Cover
(3) Body refer to the Original Equipment Manufacture
(OEM) for more information.
Remove wing nut (1) and cover (2). Check for an
accumulation of dirt and debris in body (3). Clean the
body, if necessary.
After cleaning the precleaner, install cover (2) and
wing nut (1).
Note: When the engine is operated in dusty

applications, more frequent cleaning is required.
i04725716
Engine Crankcase Breather

Element - Replace
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
Typical example
Engine Breather
2. If necessary, remove breather pipes on cover (6).
NOTICE
Remove nuts (7) and remove cover (6) from
ing or repair is performed. housing (1).
96 SEBU9068
Engine Mounts - Inspect
3. Remove circlip (4) and remove the breather i02323089

element (3) and discard.
Engine Mounts - Inspect
4. Remove the O ring seal (5) from the cover.
Install the Breather Element Note: The engine mounts may not have been
supplied by Perkins. Refer to the OEM information for
Ensure that all the components are clean and free further information on the engine mounts and the
from damage.
correct bolt torque.
Inspect the engine mounts for deterioration and for
correct bolt torque. Engine vibration can be caused
by the following conditions:
• Incorrect mounting of the engine

• Deterioration of the engine mounts
• Loose engine mounts

Any engine mount that shows deterioration should be
replaced. Refer to the OEM information for the
recommended torques.
i04728471
Engine Oil Level - Check
Illustration 56 g02827300 Hot oil and hot components can cause personal
Typical example injury. Do not allow hot oil or hot components to
(A) Diameter
contact the skin.
(B) Diameter
1. Install a new O ring seal (5) onto the cover (6).
Note: The breather element must have the correct

orientation before installation. Diameter (A) is visibly
larger than diameter (B).
2. Install diameter (A) of the breather element (3) onto
the shaft (2). When correctly installed the part
number of the breather element will be visible.
3. Install circlip (4) and cover (6). Install nuts (7) and
tighten to 25 N·m (18 lb ft). If necessary, install
breather pipes to cover.
4. Install the guard, refer to OEM. Illustration 57 g02829378

Typical example
NOTICE
Perform this maintenance with the engine stopped.
Note: Ensure that the engine is either level or that the

engine is in the normal operating position in order to
obtain a true level indication.
SEBU9068 97
Engine Oil Sample - Obtain
Note: After the engine has been switched OFF, wait • The date of the sample
for 10 minutes in order to allow the engine oil to drain
to the oil pan before checking the oil level. • Engine model
1. Maintain the oil level between the MIN mark and • Engine number
the mark MAX on the engine oil dipstick. Do not fill • Service hours on the engine
the crankcase above the MAX mark.
• The number of hours that have accumulated since
the last oil change
NOTICE
Operating your engine when the oil level is above the • The amount of oil that has been added since the
MAX mark could cause your crankshaft to dip into the last oil change
oil. The air bubbles created from the crankshaft dip-
ping into the oil reduces the oils lubricating character- Ensure that the container for the sample is clean and
istics and could result in the loss of power. dry. Also ensure that the container for the sample is
clearly labelled.
2. Remove the oil filler cap and add oil, if necessary. To ensure that the sample is representative of the oil
Clean the oil filler cap. Install the oil filler cap. in the crankcase, obtain a warm, well mixed oil
sample.
If an increase in the oil level is noticed, refer to
Troubleshooting, “Oil Contains Fuel”. To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
i01907674
The sample can be checked for the following: the
Engine Oil Sample - Obtain quality of the oil, the existence of any coolant in the
oil, the existence of any ferrous metal particles in the
oil and the existence of any nonferrous metal
particles in the oil.
The condition of the engine lubricating oil may be
checked at regular intervals as part of a preventive
maintenance program. Perkins include an oil i05859222
sampling valve as an option. The oil sampling valve
(if equipped) is included in order to regularly sample Engine Oil and Filter - Change
the engine lubricating oil. The oil sampling valve is
positioned on the oil filter head or the oil sampling
valve is positioned on the cylinder block.
Perkins recommends using a sampling valve in order
to obtain oil samples. The quality and the consistency
of the samples are better when a sampling valve is Hot oil and hot components can cause personal
used. The location of the sampling valve allows oil injury. Do not allow hot oil or hot components to
that is flowing under pressure to be obtained during contact the skin.
normal engine operation.
Obtain the Sample and the Analysis NOTICE

Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
Hot oil and hot components can cause personal before opening any compartment or disassembling
injury. Do not allow hot oil or hot components to any component containing fluids.
contact the skin.
Dispose of all fluids according to local regulations and
mandates.
In order to help obtain the most accurate analysis,
record the following information before an oil sample
is taken:
NOTICE
component life.
98 SEBU9068
Engine Oil and Filter - Change
Do not drain the engine lubricating oil when the Replace the Oil Filter
engine is cold. As the engine lubricating oil cools,
suspended waste particles settle on the bottom of the NOTICE
oil pan. The waste particles are not removed with Perkins oil filters are manufactured to Perkins specifi-
draining cold oil. Drain the oil pan with the engine cations. Use of an oil filter that is not recommended
stopped. Drain the oil pan with the oil warm. This
draining method allows the waste particles that are by Perkins could result in severe damage to the en-
suspended in the oil to be drained properly. gine bearings, crankshaft, as a result of the larger
waste particles from unfiltered oil entering the engine
Failure to follow this recommended procedure will lubricating system. Only use oil filters recommended
cause the waste particles to be recirculated through by Perkins.
the engine lubrication system with the new oil.
Drain the Engine Lubricating Oil 1. Using a suitable tool remove the engine oil filter.
Ensure that the engine is level before starting the

service procedure. Ensure that the vessel that will be
used is large enough to collect the waste oil. After the
engine has been run at the normal operating
temperature, stop the engine. Ensure that the
application that the engine is installed is on level
ground. Use one of the following methods to drain the
engine oil pan:
Typical example
2. Clean sealing surface (2).
3. Apply clean engine oil to O ring seal (3) on the new

oil filter.
Typical example NOTICE
Do not fill the oil filters with oil before installing them.
• If the engine is equipped with a drain valve, turn This oil would not be filtered and could be contami-
the drain valve knob counterclockwise in order to nated. Contaminated oil can cause accelerated wear
drain the oil. After the oil has drained, turn the to engine components.
drain valve knob clockwise in order to close the
drain valve.
4. Install the engine oil filter, spin on the oil filter until
• If the engine is not equipped with a drain valve, the O ring seal contacts the oil filter base. Then,
remove the oil drain plug (1) in order to allow the rotate the oil filter ¾ of a full turn, by hand only.
oil to drain. If the engine is equipped with a shallow
oil pan, remove the bottom oil drain plugs from
both ends of the oil pan.
After the oil has drained, replace the drain plug. If
necessary replace the seal on the drain plug. Install
drain plug and tighten to 50 N·m (36 lb ft).
SEBU9068 99
Fan Clearance - Check
Vertically Up Oil Filter
Typical example
4. Remove the engine oil level gauge in order to

check the oil level. Maintain the oil level between
the MIN mark and MAX mark on the engine oil
level gauge. Do not fill the crankcase above the
MAX mark.
(4) Vertically up oil filter i04401341
Some oil filters may be installed vertically up. Use the

same procedure in order to replace the oil filter. Fan Clearance - Check
Ensure that all the oil has drained from the filter
before removal.
There are different types of cooling systems. Refer to
Fill the Oil Pan the OEM for information on clearance for the fan.
1. Remove the oil filler cap. Refer to this Operation Ensure that the engine is stopped. Ensure that the
and Maintenance Manual, “Fluid battery disconnect switch is in the OFF position.
Recommendations” for more information on Ensure that the cooling system is full. The clearance
suitable oils. Fill the oil pan with the correct amount between the cover (1) and the fan (2) will require
checking. The gap (A) between the edge of the cover
of new engine lubricating oil. Refer to this and the tip of the fan blade must be checked in four
Operation and Maintenance Manual, “Refill equally spaced positions.
Capacities” for more information on refill
capacities.
NOTICE
If equipped with an auxiliary oil filter system or a re-
mote filter system, follow the OEM or the filter manu-
factures recommendations. Under filling or over filling
the crankcase with oil can cause engine damage.
2. Start the engine and run the engine at “LOW IDLE”

for 2 minutes. Perform this procedure in order to
ensure that the lubrication system has oil and that
the oil filters are filled. Inspect the oil filter for oil
leaks.
3. Stop the engine and allow the oil to drain back to
the oil pan for a minimum of 10 minutes.
100 SEBU9068
Fuel System - Prime
Typical example
Adjustment of the cover will change the clearance

(gap) between the edge of the cover and the tip of the NOTICE
fan blade. Ensure that the cover is centralized to the Do not crank the engine continuously for more than
fan. 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
The clearance (A) must be set to 10 ± 1 mm
(0.39370 ± 0.03937 inch).
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be
i04366913
started. Air can enter the fuel system when the
following events occur:
Fuel System - Prime
• The fuel tank is empty or the fuel tank has been
partially drained.
Note: Refer to Systems Operation, Testing, and • The low-pressure fuel lines are disconnected.
Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the • A leak exists in the low-pressure fuel system.
standards of cleanliness that must be observed
during ALL work on the fuel system. • The fuel filter has been replaced.
Ensure that all adjustments and repairs are Use the following procedures in order to remove air
performed by authorized personnel that have had the from the fuel system:
correct training.
SEBU9068 101
Fuel System Primary Filter (Water Separator) Element - Replace
1. Ensure that the fuel system is in working order. Note: Refer to Systems Operation, Testing, and
Check that the fuel supply valve (if equipped) is in Adjusting, “Cleanliness of Fuel System
the “ON” position. Components” for detailed information on the
2. Operate the hand priming pump. Count the number during ALL work on the fuel system.
of operations of the pump. After approximately 80
depression of the pump stop. NOTICE
ing or repair is performed.
Note: As the fuel system is primed, the pressure will
increase within the fuel system and this increase in
pressure can be felt during priming. Remove the Element
3. The fuel system should now be primed and the
engine should be able to start. 1. Turn the fuel supply valve (if equipped) to the OFF
position before performing this maintenance.
4. Operate the engine starter and crank the engine.
After the engine has started, operate the engine at 2. Place a suitable container under the water
low idle for a minimum of 5 minutes. Ensure that separator in order to catch any fuel that might spill.
the fuel system is free from leaks. Clean up any spilled fuel. Clean the outside body
of the filter assembly.
Note: Operating the engine for this period will help
ensure that the fuel system is free of air. DO NOT 3. Make a temporary Mark (A) across the filter before
loosen the high-pressure fuel lines in order to the assembly is removed.
purge air from the fuel system. This procedure is
not required.
After the engine has stopped, you must wait for 10
minutes in order to allow the fuel pressure to be
purged from the high-pressure fuel lines before any
service or repair is performed on the engine fuel lines.
If necessary, perform minor adjustments. Repair any
leaks from the low-pressure fuel system and from the
cooling, lubrication, or air systems. Replace any high-
pressure fuel line that has leaked. Refer to
Disassembly and Assembly Manual, “Fuel Injection
Lines - Install”.
If you inspect the engine in operation, always use the
If the engine will not start, refer to Troubleshooting,
“Engine Cranks but will not Start”.
i05326388
Fuel System Primary Filter Illustration 63 g03374220

Typical example
(Water Separator) Element -
Replace 4. Install a suitable tube onto drain (3). Open the drain
valve (2). Rotate the drain valve counterclockwise.
Two full turns are required. Loosen vent screw (1).
Note: Two complete rotations of the valve will release

the valve from the filter element.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent 5. Allow the fuel to drain into the container. Remove
possible injury, turn the start switch off when the tube and install the valve into the filter element.
changing fuel filters or water separator elements. Engage the threads of the valve into the filter
Clean up fuel spills immediately. element. Do not secure the valve.
102 SEBU9068
Fuel System Primary Filter (Water Separator) Element - Replace
6. Tighten the vent screw (1) securely . Remove the

wiring harness from connection (4).
Typical example
Illustration 64 g03374223 1. Locate the thread in the filter element (8) onto the
Typical example threads (9). Spin on the element. Do not tighten.
7. Using a suitable tool, remove the filter bowl (6). 2. Lubricate the O ring seal (7) with clean engine oil.
Rotate the filter assembly counterclockwise in Do NOT fill the bowl with fuel before the assembly
order to remove the filter assembly. Use a suitable is installed.
tool in order to remove the filter assembly.
3. Do NOT use a tool in order to install the filter
8. Rotate the filter element counterclockwise and assembly. Tighten the filter bowl (6) by hand.
remove the filter element (5). Clean the filter bowl. Install the filter bowl (6) and align with your
temporary marks (A).
Install the Element
4. Tighten the valve (2) securely. Remove the
container and dispose of the fuel in a safe place.
5. The secondary filter element must be replaced at

the same time as the primary filter element. Refer
to the Operation and Maintenance Manual, “Fuel
System Filter - Replace”.
SEBU9068 103
Fuel System Primary Filter/Water Separator - Drain
i05326334 3. Install a suitable tube onto drain (3). Open the drain
valve (2). Rotate the drain valve counterclockwise.
Fuel System Primary Filter/ Two full turns are required. Loosen vent screw (1).
Water Separator - Drain Note: Two complete rotations of the valve will release
4. Allow the fluid to drain into the container.
5. Engage the threads of the valve into the filter
Fuel leaked or spilled onto hot surfaces or electri- element and tighten the drain valve by hand
cal components can cause a fire. To help prevent pressure only. Tighten vent screw securely.
possible injury, turn the start switch off when
changing fuel filters or water separator elements. 6. Remove the tube and remove the container.
Clean up fuel spills immediately.
i04367528
NOTICE Fuel System Secondary Filter -

ing or repair is performed. Replace
NOTICE
The water separator can be under suction during nor-
mal engine operation. Ensure that the drain valve is
tightened securely to help prevent air from entering Fuel leaked or spilled onto hot surfaces or electri-
the fuel system. cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
1. Place a suitable container under the water Clean up fuel spills immediately.
separator in order to catch any fluid that might spill.
Clean up any spilled fluid.
NOTICE
2. Ensure that the outer body of the filter assembly is Ensure that the engine is stopped before any servic-
clean and free from dirt. ing or repair is performed.
Refer to Systems Operation, Testing, and

Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the
during ALL work on the fuel system.
Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFF
position before performing this maintenance.
2. Place a suitable container under the fuel filter in

order to catch any fuel that might spill. Clean up
any spilled fuel. Clean the outside body of the filter
assembly.
Typical example
104 SEBU9068
Fuel System Secondary Filter - Replace
Illustration 67 g02522536 Illustration 68 g02522538

Typical example Typical example
3. Make a temporary Mark (A) across the filter before 7. Rotate the filter element counterclockwise and
the assembly is removed. Install a suitable tube remove the filter element (5). Clean the filter bowl.
onto drain (4). Open the drain valve (3). Rotate the
drain valve counterclockwise. Two full turns are Install the Element
required. Loosen vent screw (1).
Note: Two complete rotations of the valve will release
4. Allow the fuel to drain into the container. Remove
the tube and install the valve into the filter element.
Engage the threads of the valve into the filter
element. Do not secure the valve.
5. Tighten the vent screw (1) securely.
6. Remove the filter bowl (2). Rotate the filter

assembly counterclockwise in order to remove the
assembly. Use a suitable tool in order to remove
the filter bowl.
Typical example
1. Locate the thread in the filter element (7) onto the

threads (8). Spin on the element. Do not tighten.
2. Lubricate the O ring seal (6) with clean engine oil.

Do NOT fill the filter bowl (2) with fuel before the
filter assembly is installed.
SEBU9068 105
Fuel Tank Water and Sediment - Drain
Open the drain valve on the bottom of the fuel tank in

3. Do not use a tool in order to install the filter order to drain the water and the sediment. Close the
assembly. Tighten the assembly by hand. Install drain valve.
the filter bowl (2) and align with your temporary Check the fuel daily. Allow five minutes after the fuel
Marks. tank has been filled before draining water and
sediment from the fuel tank.
4. Tighten the drain valve (3). Turn the fuel supply
valve to the ON position. Fill the fuel tank after operating the engine in order to
drive out moist air. This will help prevent
5. The Primary filter element must be replaced at the condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
same time as the secondary filter element. Refer to overflow.
the Operation and Maintenance Manual, “Fuel
System Primary Filter (Water Separator) Element - Some fuel tanks use supply pipes that allow water
Replace”. and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If the
6. Prime the fuel system. Refer to the Operation and
engine is equipped with this system, regular
Maintenance Manual, “Fuel System - Prime” for maintenance of the fuel system filter is important.
more information.
Fuel Storage Tanks
i02348492
Drain the water and the sediment from the fuel
Fuel Tank Water and Sediment storage tank at the following intervals:
- Drain • Weekly
• Service intervals
• Refill of the tank
NOTICE
Care must be taken to ensure that fluids are con- This will help prevent water or sediment from being
tained during performance of inspection, mainte- pumped from the storage tank into the engine fuel
nance, testing, adjusting and repair of the product. Be tank.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
any component containing fluids. settle before filling the engine fuel tank. Internal
Dispose of all fluids according to local regulations and baffles in the bulk storage tank will also help trap
mandates. sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
Fuel Tank
i02518232
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system.
Hoses and Clamps - Inspect/
Water can be introduced into the fuel tank when the
Replace
fuel tank is being filled.
Condensation occurs during the heating and cooling
of fuel. The condensation occurs as the fuel passes
through the fuel system and the fuel returns to the
fuel tank. This causes water to accumulate in fuel Contact with high pressure fuel may cause fluid
tanks. Draining the fuel tank regularly and obtaining penetration and burn hazards. High pressure fuel
fuel from reliable sources can help to eliminate water spray may cause a fire hazard. Failure to follow
in the fuel. these inspection, maintenance and service in-
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining If you inspect the engine in operation, always use the
water and draining sediment from the bottom of the proper inspection procedure in order to avoid a fluid
fuel tanks. penetration hazard. Refer to Operation and
106 SEBU9068
Radiator - Clean
Inspect all hoses for leaks that are caused by the

following conditions:
• Cracking Pressurized System: Hot coolant can cause seri-

• Softness stop the engine and wait until the cooling system
• Loose clamps pressure cap slowly in order to relieve the
pressure.
Replace hoses that are cracked or soft. Tighten any
loose clamps.
1. Stop the engine. Allow the engine to cool.
Check for the following conditions:
2. Loosen the cooling system filler cap slowly in order
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut system filler cap.
• Exposed wire that is used for reinforcement

Note: Drain the coolant into a suitable, clean
• Outer covering that is ballooning locally container. The coolant can be reused.
3. Drain the coolant from the cooling system to a level
• Flexible part of the hose that is kinked or crushed that is below the hose that is being replaced.
• Armoring that is embedded in the outer covering 4. Remove the hose clamps.
A constant torque hose clamp can be used in place of 5. Disconnect the old hose.
any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard 6. Replace the old hose with a new hose.
clamp.
Due to extreme temperature changes, the hose will 7. Install the hose clamps with a torque wrench.
harden. Hardening of the hoses will cause hose
clamps to loosen. This can result in leaks. A constant Note: For the correct coolant, see this Operation and
torque hose clamp will help to prevent loose hose Maintenance Manual, “Fluid Recommendations”.
clamps.
8. Refill the cooling system. Refer to the OEM
Each installation application can be different. The information for further information on refilling the
differences depend on the following factors: cooling system.
• Type of hose 9. Clean the cooling system filler cap. Inspect the
cooling system filler cap's seals. Replace the
• Type of fitting material
cooling system filler cap if the seals are damaged.
• Anticipated expansion and contraction of the hose Install the cooling system filler cap.
• Anticipated expansion and contraction of the 10. Start the engine. Inspect the cooling system for
fittings leaks.
Replace the Hoses and the Clamps i02335774
Refer to the OEM information for further information

on removing and replacing fuel hoses (if equipped). Radiator - Clean
The following text describes a typical method of
replacing coolant hoses. Refer to the OEM The radiator is not usually supplied by Perkins. The
information for further information on the coolant following text describes a typical cleaning procedure
system and the hoses for the coolant system.
for the radiator. Refer to the OEM information for
further information on cleaning the radiator.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the radiator for these items: Damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.
SEBU9068 107
Starting Motor - Inspect
i04407666
Personal injury can result from air pressure.

Turbocharger - Inspect
Personal injury can result without following prop-
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less Hot engine components can cause injury from
than 205 kPa (30 psi) for cleaning purposes. burns. Before performing maintenance on the en-
gine, allow the engine and the components to
Pressurized air is the preferred method for removing cool.
loose debris. Direct the air in the opposite direction to
the fan's air flow. Hold the nozzle approximately 6 mm
(0.25 inch) away from the radiator fins. Slowly move NOTICE
the air nozzle in a direction that is parallel with the Turbocharger bearing failures can cause large quanti-
radiator tube assembly. This will remove debris that is ties of oil to enter the air intake and exhaust systems.
between the tubes. Loss of engine lubricant can result in serious engine
Pressurized water may also be used for cleaning. The damage.
maximum water pressure for cleaning purposes must Minor leakage of oil into a turbocharger under ex-
be less than 275 kPa (40 psi). Use pressurized water tended low idle operation should not cause problems
in order to soften mud. Clean the core from both as long as a turbocharger bearing failure has not
sides.
occurred.
Use a degreaser and steam for removal of oil and
When a turbocharger bearing failure is accompanied
grease. Clean both sides of the core. Wash the core
by a significant engine performance loss (exhaust
with detergent and hot water. Thoroughly rinse the
core with clean water. smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is renewed.
If the radiator is blocked internally, refer to the OEM
Manual for information regarding flushing the cooling
system. A visual inspection of the turbocharger can minimize
unscheduled downtime. A visual inspection of the
After cleaning the radiator, start the engine. Allow the turbocharger can also reduce the chance for potential
engine to operate at low idle speed for three to five damage to other engine parts. Do not inspect the
minutes. Accelerate the engine to high idle. This will engine with the engine in operation.
help in the removal of debris and the drying of the
core. Slowly reduce the engine speed to low idle and
then stop the engine. Use a light bulb behind the core
in order to inspect the core for cleanliness. Repeat
the cleaning, if necessary.
Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition:
Welds, mounting brackets, air lines, connections,
clamps and seals. Make repairs, if necessary.
i02177969
Starting Motor - Inspect
Perkins recommends a scheduled inspection of the

starting motor. If the starting motor fails, the engine
may not start in an emergency situation.
Check the starting motor for correct operation. Check
the electrical connections and clean the electrical
connections. Refer to the Systems Operation, Testing Illustration 70 g02603804
and Adjusting Manual, “Electric Starting System - Typical example
Test” for more information on the checking procedure
and for specifications or consult your Perkins dealer
or your Perkins distributor for assistance.
108 SEBU9068
Walk-Around Inspection
1. Ensure that the turbocharger is clean and free from

NOTICE
dirt before removing components for inspection.
For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and
2. Remove the air intake pipe (1). Visually inspect the
correct the leak. If leaking is suspected, check the flu-
piping for the presence of oil. A small amount oil id levels more often than recommended until the leak
will be expected, this oil is due to the breather is found or fixed, or until the suspicion of a leak is
system design. Clean the interior of the pipe in proved to be unwarranted.
order to prevent dirt from entering during
reassembly.
NOTICE
3. Check for obvious heat discoloration of the Accumulated grease and/or oil on an engine is a fire
turbocharger. Check for any loose bolts or any hazard. Remove the accumulated grease and oil. Re-
missing bolts. Check for damage to the oil supply fer to this Operation and Maintenance Manual, “En-
line (3) and the oil drain line (2). Check for cracks gine - Clean” for more information.
in the housing of the turbocharger. Ensure that the
compressor wheel can rotate freely. Check that
• Ensure that the cooling system hoses are correctly
there are no visual signs of damage to the
clamped and that the cooling system hoses are
compressor wheel. tight. Check for leaks. Check the condition of all
pipes.
4. Check for the presence of oil. If oil is leaking from
the back side of the compressor wheel, there is a • Inspect the water pump for coolant leaks.
possibility of a failed turbocharger oil seal.
Note: The water pump seal is lubricated by the
The presence of oil may be the result of extended coolant in the cooling system. A small amount of
engine operation at low idle. The presence of oil leakage is normal and can occur as the engine cools
may also be the result of a restriction of the line for down and the parts contract.
the intake air (clogged air filters). A restriction can
cause the turbocharger to slobber. Excessive coolant leakage may indicate the need to
replace the water pump. Remove the water pump.
5. Install the air intake pipe to the turbocharger Refer to Disassembly and Assembly, “Water Pump -
housing. Ensure that all clamps are installed Remove and Install”. For more information, consult
correctly and that all clamps are tightened your Perkins dealer or your Perkins distributor .
securely. For more information, refer to Systems
• Inspect the lubrication system for leaks at the front
Operation, Testing, and Adjusting, “Turbocharger - crankshaft seal, the rear crankshaft seal, the oil
Inspect”. pan, the oil filters, and the rocker cover.
i05859232 • Inspect the piping for the air intake system and the
elbows for cracks and for loose clamps. Ensure
Walk-Around Inspection that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses.
• Ensure that the areas around the rotating parts are

Inspect the Engine for Leaks and clear.
for Loose Connections • Inspect the alternator belts and any accessory
drive belts for cracks, breaks, or other damage.
A walk-around inspection should only take a few
minutes. When the time is taken to perform these • Inspect the wiring harness for damage.
checks, costly repairs and accidents can be avoided.
Belts for multiple groove pulleys must be replaced as
For maximum engine service life, make a thorough matched sets. If only one belt is replaced, the belt will
inspection of the engine compartment before starting carry more load than the belts that are not replaced.
the engine. Look for items such as oil leaks or coolant The older belts are stretched. The additional load on
leaks, loose bolts, worn belts, loose connections, and the new belt could cause the belt to break.
trash buildup. Make repairs, as needed:
• The guards must be in the correct place. Repair
damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system
contamination.
SEBU9068 109
Water Pump - Inspect
High Pressure Fuel Lines Aftertreatment System

Check the condition of the coolant lines, Diesel
Exhaust Fluid (DEF) lines, and electrical connections.
Check that all clamps, clips, and tie-wraps are secure
Contact with high pressure fuel may cause fluid and in good condition. Check that the DEF filler cap is
penetration and burn hazards. High pressure fuel secure and that the cap is clean and free from dirt.
these inspection, maintenance and service in- i04406817
Water Pump - Inspect
After the engine has stopped, you must wait for 10
minutes in order to allow the fuel pressure to be
purged from the high-pressure fuel lines before any A failed water pump may cause severe engine
service or repair is performed on the engine fuel lines. overheating problems that could result in the following
If necessary, perform minor adjustments. Repair any conditions:
leaks from the low-pressure fuel system and from the
cooling, lubrication, or air systems. Replace any high- • Cracks in the cylinder head
pressure fuel line that has leaked. Refer to
Disassembly and Assembly Manual, “Fuel Injection • A piston seizure
Lines - Install”.
• Other potential damage to the engine
If you inspect the engine in operation, always use the
Visually inspect the high-pressure fuel lines for
damage or signs of fuel leakage. Replace any
damaged high-pressure fuel lines or high-pressure
fuel lines that have leaked.
Ensure that all clips on the high-pressure fuel lines
are in place and that the clips are not loose.
• Inspect the rest of the fuel system for leaks. Look
for loose fuel line clamps.
• Drain the water and the sediment from the fuel

tank on a daily basis in order to ensure that only
clean fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires. Check for any loose tie-wraps or missing tie-
wraps.
• Inspect the ground strap for a good connection Typical example
and for good condition. (1) Weep hole
• Disconnect any battery chargers that are not Note: The water pump seals are lubricated by the
protected against the current drain of the starting coolant in the cooling system.
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is Visually inspect the water pump for leaks.
equipped with a maintenance free battery.
Note: If engine coolant enters the engine lubricating
• Check the condition of the gauges. Replace any system, the lubricating oil and the engine oil filter
gauges that are cracked. Replace any gauge that must be replaced. Draining will remove any
cannot be calibrated. contaminate and will prevent any irregular oil
samples.
In order to install a new water pump, refer to the
Disassembly and Assembly Manual, “Water Pump -
Remove and Install”.
110 SEBU9068
Warranty Section
Emissions Warranty Information
Warranty Section The aftertreatment system can be expected to

function properly for the lifetime of the engine
(emissions durability period) subject to prescribed
maintenance requirements being followed.
Warranty Information
A detailed explanation of the Emission Control
Warranty is available to view on Perkins. com service
i05680169 and support.
Emissions Warranty
Information
The certifying engine manufacturer warrants to the

ultimate purchaser and each subsequent purchaser
that:
1. New non-road diesel engines and stationary diesel
engines less than 10 L per cylinder (including Tier
1 and Tier 2 marine engines < 37 kW, but
excluding locomotive and other marine engines)
operated and serviced in the United States and
Canada, including all parts of their emission control
systems (“emission related components”), are:
a. Designed, built, and equipped so as to

conform, at the time of sale, with applicable
emission standards prescribed by the United
States Environmental Protection Agency
(EPA) by way of regulation.
b. Free from defects in materials and

workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (including Tier 1 and

Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to
conform, at the time of sale, to all applicable
regulations adopted by the California Air
Resources Board (ARB).
b. Free from defects in materials and

workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.
SEBU9068 111
Reference Information Section
Maintenance Records
Reference Information • Dealer work orders and itemized bills
Section • Owners repair costs
• Owners receipts
Reference Materials • Maintenance log
i05204672
Maintenance Records
Perkins recommends the retention of accurate

maintenance records. Accurate maintenance records
can be used for the following purposes:
• Determine operating costs.
• Establish maintenance schedules for other

engines that are operated in the same
environment.
• Show compliance with the required maintenance

practices and maintenance intervals.
Maintenance records can be used for various other
business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is correctly managed.
Accurate maintenance records can help your Perkins
dealer to fine-tune the recommended maintenance
intervals in order to meet the specific operating
situation. This should result in a lower engine
operating cost.
Records should be kept for the following items:
Fuel Consumption – A record of fuel consumption is
essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.
Service Hours – A record of service hours is
essential to determine when the speed sensitive
components should be inspected or repaired.
Documents – These items should be easy to obtain,
and these items should be kept in the engine history
file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number and engine serial number. The following
types of documents should be kept as proof of
maintenance or repair for warranty:
Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
112 SEBU9068
Reference Materials
Maintenance Log
i05204675
Maintenance Log
Table 23
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity Of
Service Item Date Authorization
Hours Fuel
SEBU9068 113
Reference Materials
Reference Material
i05204677
Reference Material
(Extended Service Contract)
Extended Service Contracts-purchased in minutes,

protected for years.
Extended Service Contracts (ESC) protect you from
the stress that unexpected repair work brings to your
life bt covering the cost of getting your engine up and
running again. Unlike other extended warranties,
Perkins Platinum ESC protects you against all
component part failures.
Purchase peace of mine from only £0.03 / $0.05 /
euro 0.04 a day and let an ESC make your dreams a
reality.
Why buy an Extended Service Contract?
1. No surprises - total protection from unexpected

repair cost (parts, labor, and travel).
2. Enjoy longer lasting product support from Perkins

global network.
3. Genuine Perkins parts ensure continued engine

performance.
4. Highly trained technicians carry out all repairs.
5. Transferable coverage should you sell your

machine.
Flexible coverage provides the right level of
protection for your Perkins Engine. Coverage can be
extended to 2 years/ 1,000 hours right up to 10 year/
40,000
You can buy an ESC at any time during standard
warranty - even the last day!
Each Perkins Distributor has highly trained and
experienced Perkins Product Support Service
Technicians. The Support Service are equipped, and
available around the clock to get your engine running
again with the minimum of downtime. Buying an ESC
means that you get all this for free.
To purchase an Extended Service Contract, is quick
and simple! Contact your local Perkins Distributor
now and the distributor can provide you with a quote
in minutes. You can locate your nearest Perkins
Distributor by visiting:
www.perkins.com
NOTICE
Dependant upon engine type and application.
114 SEBU9068
Index Section
Index
A Coolant Extender (ELC) - Add ......................... 86
Coolant Level - Check ..................................... 86
After Starting Engine........................................ 51
Engine with Radiator Installed by OEM ....... 87
After Stopping Engine...................................... 58
Engine with Radiator Installed by the Engine
Aftercooler Core - Clean/Test (Air-To-Air
Manufacturer.............................................. 86
Aftercooler) .................................................... 79
Crushing Prevention and Cutting Prevention .. 12
Aftercooler Core - Inspect................................ 79
Alarms and Shutoffs ........................................ 29
Alarms.......................................................... 29 D
Shutoffs........................................................ 29
Testing.......................................................... 30 DEF Filler Screen - Clean................................ 87
Alternator - Inspect .......................................... 79 DEF Manifold Filters - Replace........................ 88
Alternator and Fan Belts - Replace.................. 79 Diagnostic Lamp.............................................. 45
Diesel Exhaust Fluid - Fill ................................ 88
Diesel Exhaust Fluid Filter - Clean/Replace.... 89
B Diesel Exhaust Fluid in Cold Weather ............. 57
Diesel Exhaust Fluid Tank - Flush ................... 90
Battery - Replace............................................. 80
Driven Equipment - Check............................... 90
Battery Disconnect Switch............................... 35
Battery Electrolyte Level - Check .................... 81
Battery or Battery Cable - Disconnect ............. 81 E
Before Starting Engine ...............................14, 49
Burn Prevention................................................. 9 Electrical System ............................................. 15
Aftertreatment System ................................. 10 Grounding Practices .................................... 16
Batteries....................................................... 10 Emergency Stopping ....................................... 58
Coolant......................................................... 10 Emergency Stop Button............................... 58
Diesel Fuel ................................................... 10 Emissions Certification Film ............................ 25
Induction System ......................................... 10 Emissions Warranty Information.....................110
Oils............................................................... 10 Engaging the Driven Equipment...................... 52
Engine - Clean ................................................. 90
Aftertreatment .............................................. 91
C Engine Air Cleaner Element (Dual Element)
- Inspect/Clean/Replace ................................ 91
Cold Weather Operation.................................. 54
Cleaning the Primary Air Cleaner Elements
Hints for Cold Weather Operation................ 54
................................................................... 92
Idling the Engine .......................................... 55
Servicing the Air Cleaner Elements ............. 91
Recommendations for Coolant Warm Up .... 55
Engine Air Cleaner Element (Single
Recommendations for the Coolant .............. 55
Element) - Inspect/Replace ........................... 93
Viscosity of the Engine Lubrication Oil......... 55
Engine Air Cleaner Service Indicator -
Cold Weather Starting ..................................... 49
Inspect ........................................................... 94
Configuration Parameters................................ 46
Test the Service Indicator............................. 94
Customer Specified Parameters.................. 46
Engine Air Precleaner - Check/Clean (If
System Configuration Parameters............... 46
Equipped) ...................................................... 95
Coolant (DEAC) - Change ............................... 82
Engine Crankcase Breather Element -
Drain ............................................................ 82
Replace.......................................................... 95
Fill................................................................. 83
Engine Breather........................................... 95
Flush ............................................................ 83
Engine Diagnostics.......................................... 45
Coolant (ELC) - Change .................................. 84
Engine Electronics........................................... 17
Drain ............................................................ 84
Engine Mounts - Inspect.................................. 96
Fill................................................................. 85
Engine Oil and Filter - Change ........................ 97
Flush ............................................................ 85
SEBU9068 115
Index Section
Drain the Engine Lubricating Oil .................. 98 Fuel System Primary Filter (Water Separator)
Fill the Oil Pan.............................................. 99 Element - Replace ....................................... 101
Replace the Oil Filter.................................... 98 Install the Element ..................................... 102
Engine Oil Level - Check ................................. 96 Remove the Element ................................. 101
Engine Oil Sample - Obtain ............................. 97 Fuel System Primary Filter/Water Separator
Obtain the Sample and the Analysis............ 97 - Drain .......................................................... 103
Engine Operation............................................. 52 Fuel System Secondary Filter - Replace ....... 103
Aftertreatment .............................................. 52 Install the Element ..................................... 104
System check............................................... 52 Remove the Element ................................. 103
Engine Operation with Active Diagnostic Fuel Tank Water and Sediment - Drain.......... 105
Codes ............................................................ 45 Drain the Water and the Sediment............. 105
Engine Operation with Intermittent Fuel Storage Tanks .................................... 105
Diagnostic Codes........................................... 45 Fuel Tank ................................................... 105
Engine Starting ...........................................15, 49
Engine Stopping .........................................15, 58
G
Gauges and Indicators .................................... 35
F Indicator Lamps ........................................... 36
Fan Clearance - Check.................................... 99 Instrument panels and Displays................... 36
Fault Logging................................................... 45 General Hazard Information .............................. 5
Features and Controls ..................................... 29 Containing Fluid Spillage ............................... 8
Fire Prevention and Explosion Prevention ...... 10 Diesel Exhaust Fluid ...................................... 9
Ether ............................................................ 12 Dispose of Waste Properly............................. 9
Fire Extinguisher.......................................... 12 Fluid Penetration............................................ 7
Lines, Tubes, and Hoses ............................. 12 Inhalation ....................................................... 8
Fluid Recommendations...................... 61–62, 68 Pressurized Air and Water ............................. 7
Diesel Fuel Characteristics .......................... 71 Static Electricity Hazard when Fueling with
Diesel Fuel Requirements............................ 68 Ultra-low Sulfur Diesel Fuel.......................... 8
ELC Cooling System Maintenance.............. 65 General Information......................................... 18
Engine Oil .................................................... 61
General Coolant Information........................ 62
General Information ..................................... 68 H
General Lubricant Information ..................... 61 High Pressure Fuel Lines ................................ 13
Fluid Recommendations (Diesel Exhaust Hoses and Clamps - Inspect/Replace ........... 105
Fluid (DEF)) ................................................... 67 Replace the Hoses and the Clamps .......... 106
General Information ..................................... 67
Foreword............................................................ 4
California Proposition 65 Warning ................. 4 I
Literature Information..................................... 4 Important Safety Information ............................. 2
Maintenance .................................................. 4
Maintenance Intervals.................................... 4
Operation ....................................................... 4 L
Overhaul ........................................................ 4 Lifting and Storage........................................... 26
Safety............................................................. 4
Fuel and the Effect from Cold Weather............ 56
Fuel Conservation Practices............................ 53 M
Fuel Related Components in Cold Weather .... 57 Maintenance Interval Schedule ....................... 78
Fuel Filters ................................................... 57 Commissioning ............................................ 78
Fuel Heaters ................................................ 57 Daily ............................................................. 78
Fuel Tanks.................................................... 57 Every 10 000 Service Hours ........................ 78
Fuel System - Prime ...................................... 100
116 SEBU9068
Index Section
Every 1000 Service Hours ........................... 78 Product Storage (Engine and Aftertreatment)
Every 12 000 Service Hours or 6 Years ....... 78 ....................................................................... 27
Every 1500 Service Hours ........................... 78 Aftertreatment .............................................. 27
Every 2000 Service Hours ........................... 78 Condition for Storage ................................... 27
Every 3000 Service Hours ........................... 78
Every 3000 Service Hours or 2 Years .......... 78
Every 4000 Service Hours ........................... 78 R
Every 50 Service Hours or Weekly .............. 78 Radiator - Clean............................................. 106
Every 500 Service Hours ............................. 78 Radiator Restrictions ....................................... 56
Every 500 Service Hours or 1 Year.............. 78 Reference Information..................................... 25
Every 6000 Service Hours or 3 Years .......... 78 Record for Reference................................... 25
Every Week.................................................. 78 Reference Information Section ....................... 111
When Required............................................ 78 Reference Material (Extended Service
Maintenance Log ............................................112 Contract) .......................................................113
Maintenance Recommendations..................... 75 Reference Materials ....................................... 111
Maintenance Records..................................... 111 Refill Capacities............................................... 60
Maintenance Section ....................................... 60 Cooling System............................................ 60
Model View Illustrations................................... 18 Diesel Exhaust Fluid (DEF).......................... 60
Engine with Rear Mounted Aftertreatment... 18 Lubrication System ...................................... 60
Off Engine Components............................... 21
Monitoring System........................................... 39
Programmable Options and Systems S
Operation ................................................... 39 Safety Messages ............................................... 5
Monitoring System (Table for the Indicator Universal Warning.......................................... 5
lamps) ............................................................ 37 Safety Section ................................................... 5
Mounting and Dismounting.............................. 13 Selective Catalytic Reduction Warning
System........................................................... 30
Inducement for low-level DEF...................... 31
O
Warning Indicators ....................................... 30
Operation Section............................................ 26 Warning Levels ............................................ 31
Overspeed....................................................... 39 Warning Strategy ......................................... 30
Self-Diagnostics............................................... 45
Sensors and Electrical Components ............... 41
P Engine Views ............................................... 41
Plate Locations and Film Locations................. 24 Off Engine Electrical Components............... 44
Serial Number location................................. 24 Severe Service Application.............................. 77
Plate Locations and Film Locations Incorrect Maintenance Procedures.............. 77
(Aftertreatment).............................................. 24 Severe Environmental Factors .................... 77
Product Description ......................................... 21 Severe Operating Conditions....................... 77
Aftermarket Products and Perkins Engines Starting Motor - Inspect ................................. 107
................................................................... 23 Starting the Engine .......................................... 50
Aftertreatment System ................................. 23 Starting the Engine ...................................... 50
Electronic Engine Features.......................... 22 Starting with Jump Start Cables ...................... 50
Engine Cooling and Lubrication................... 22 Stopping the Engine ........................................ 58
Engine Diagnostics ...................................... 22 System Pressure Release............................... 75
Engine Service Life ...................................... 23 Coolant System............................................ 75
Engine Specifications .................................. 21 Engine Oil .................................................... 75
Product Identification Information.................... 24 Fuel System ................................................. 75
Product Information Section ............................ 18
Product Lifting.................................................. 26
SEBU9068 117
Index Section
T
Table of Contents............................................... 3
Turbocharger - Inspect .................................. 107
W
Walk-Around Inspection ................................ 108
Aftertreatment System ............................... 109
High Pressure Fuel Lines........................... 109
Inspect the Engine for Leaks and for Loose
Connections ............................................. 108
Warranty Information ......................................110
Warranty Section ............................................110
Water Pump - Inspect .................................... 109
Welding on Engines with Electronic Controls .. 75
118 SEBU9068
Index Section
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:
Dealer Information
Name: Branch:
Address:
Dealer Phone Hours

Contact Number
Sales:
Parts:
Service:
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SEBU9068

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Maintenance Section

Foreword.............................. ............................. 4 Refill Capacities....................... ....................... 60

Maintenance Recommendations.......... .......... 75

General Hazard Information ............... .............. 5

Burn Prevention........................ ........................ 9 Warranty Information .................. ...................110

Fire Prevention and Explosion Prevention ... .. 10 Reference Information Section

Crushing Prevention and Cutting Prevention . 12 Reference Materials ................... ...................111

Mounting and Dismounting............... .............. 13 Index Section

High Pressure Fuel Lines ................ ............... 13 Index............................... ...............................114

Before Starting Engine ................. .................. 14

Engine Starting ........................ ....................... 15

Engine Stopping ....................... ...................... 15

Electrical System ...................... ...................... 15

Engine Electronics..................... ..................... 17

Product Information Section

General Information.................... .................... 18

Product Identification Information.......... ......... 24

Lifting and Storage..................... ..................... 26

Features and Controls .................. .................. 29

Engine Diagnostics..................... .................... 45

Engine Starting ........................ ....................... 49

Engine Operation...................... ...................... 52

Cold Weather Operation................. ................ 54

Engine Stopping ....................... ...................... 58

Foreword Recommended service should be performed at the

There may be several specific warning signs on your

Universal Warning General Hazard Information

Do not operate or work on this equipment unless

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

Illustration 1 g01154807 Do not allow unauthorized personnel on the engine,

• Start the engine from the operators station (cab).

• Filler caps • The engine is stopped. Ensure that the engine

• Use all cleaning solutions with care.

Avoid static electricity risk when fueling. Ultra-low

Always use a board or cardboard when you check for

Containing Fluid Spillage

• Never use compressed air for cleaning. Diesel Exhaust Fluid

Contact with high pressure fuel may cause fluid

After the engine has stopped, wait for 10 minutes in

Induction System Batteries

Lines, Tubes, and Hoses

• End fittings are damaged or leaking.

• Wires are exposed.

• Flexible parts of the hoses are kinked.

Mounting and Dismounting

Do not climb on the engine or the engine

High Pressure Fuel Lines

Contact with high pressure fuel may cause fluid

Engine exhaust contains products of combustion

Inspect the engine for potential hazards.

Engine Starting i02234873

Stop the engine according to the procedure in the

Check the electrical wires daily for wires that are

Correct grounding for the engine electrical system is

i04346349 The Engine Monitoring package can vary for different

Tampering with the electronic system installation