Руководство для ремонта двигателя перкинс

• Important Safety InformationMost accidents that involve product
  operation, maintenance and repair are caused by failure toobserve
  basic safety rules or precautions. An accident can often be avoided
  by recognizing potentiallyhazardous situations before an accident
  occurs. A person must be alert to potential hazards. Thisperson
  should also have the necessary training, skills and tools to
  perform these functions properly.

  Improper operation, lubrication, maintenance or repair of this
  product can be dangerous andcould result in injury or death.Do not
  operate or perform any lubrication, maintenance or repair on this
  product, until you haveread and understood the operation,
  lubrication, maintenance and repair information.Safety precautions
  and warnings are provided in this manual and on the product. If
  these hazardwarnings are not heeded, bodily injury or death could
  occur to you or to other persons.

  The hazards are identified by the Safety Alert Symbol and
  followed by a Signal Word such asDANGER, WARNING or CAUTION. The
  Safety Alert WARNING label is shown below.

  The meaning of this safety alert symbol is as follows:

  Attention! Become Alert! Your Safety is Involved.The message
  that appears under the warning explains the hazard and can be
  either written orpictorially presented.

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

  Perkins cannot anticipate every possible circumstance that might
  involve a potential hazard. Thewarnings in this publication and on
  the product are, therefore, not all inclusive. If a tool,
  procedure,work method or operating technique that is not
  specifically recommended by Perkins is used,you must satisfy
  yourself that it is safe for you and for others. You should also
  ensure that theproduct will not be damaged or be made unsafe by the
  operation, lubrication, maintenance orrepair procedures that you
  choose.The information, specifications, and illustrations in this
  publication are on the basis of information thatwas available at
  the time that the publication was written. The specifications,
  torques, pressures,measurements, adjustments, illustrations, and
  other items can change at any time. These changes canaffect the
  service that is given to the product. Obtain the complete and most
  current information beforeyou start any job. Perkins dealers or
  Perkins distributors have the most current information
  available.

  When replacement parts are required for thisproduct Perkins
  recommends using Perkins

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

  AndreP

• 3Table of Contents

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

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

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

  Burn Prevention
  ……………………………………………… 9

  Fire Prevention and Explosion Prevention ………… 10

  Crushing Prevention and Cutting Prevention …….. 12

  Before Starting Engine
  …………………………………… 12

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

  Engine Stopping
  …………………………………………… 13

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

  Product Information SectionModel Views
  ………………………………………………… 14

  Product Identification Information ……………………
  19

  Operation SectionLifting and Storage
  ………………………………………… 21

  Gauges and Indicators ……………………………………
  24

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

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

  Engine Stopping
  …………………………………………… 29

  Cold Weather Operation …………………………………
  30

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

  Fuel Specifications
  ………………………………………… 38

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

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

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

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

  Index SectionIndex
  ……………………………………………………………
  70

• 4Foreword

  Foreword

  Literature Information

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

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

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

  Safety

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

  Operation

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

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

  Maintenance

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

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

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

  Maintenance Intervals

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

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

  Overhaul

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

• 5Foreword

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

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

• 6Safety SectionSafety Signs and Labels

  Safety Sectioni01933317

  Safety Signs and Labels

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

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

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

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

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

• 7Safety Section

  Safety Signs and Labels

  g01000440Illustration 1

• 8Safety SectionGeneral Hazard Information

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

  g00934493

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

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

  g00283559

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

  i01884947

  General Hazard Information

  g00104545Illustration 2

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

  g00702020Illustration 3

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

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

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

  Keep the engine free from foreign material. Removedebris, oil,
  tools, and other items from the deck,from walkways, and from
  steps.

  Never put maintenance fluids into glass containers.Drain all
  liquids into a suitable container.

  Obey all local regulations for the disposal of liquids.

• 9Safety Section

  Burn Prevention

  Use all cleaning solutions with care. Report allnecessary
  repairs.

  Do not allow unauthorized personnel on theequipment.

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

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

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

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

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

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

  g00687600Illustration 4

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

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

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

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

  Obey all local regulations for the disposal of liquids.

  i01480768

  Burn Prevention

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

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

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

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

• 10Safety SectionFire Prevention and Explosion Prevention

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

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

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

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

  i01885715

  Fire Prevention and ExplosionPrevention

  g00704000Illustration 5

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

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

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

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

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

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

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

  Do not expose the engine to any flame.

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

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

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

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

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

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

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

• 11Safety Section

  Fire Prevention and Explosion Prevention

  g00704059Illustration 6

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

  g00704135Illustration 7

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

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

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

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

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

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

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

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

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

  Replace the parts if any of the following conditionsare
  present:

  End fittings are damaged or leaking.

  Outer coverings are chafed or cut.

  Wires are exposed.

  Outer coverings are ballooning.

  Flexible part of the hoses are kinked.

  Outer covers have embedded armoring.

  End fittings are displaced.

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

• 12Safety SectionCrushing Prevention and Cutting Prevention

  i01359666

  Crushing Prevention andCutting Prevention

  Support the component properly when workbeneath the component is
  performed.

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

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

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

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

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

  i01805780

  Before Starting Engine

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

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

  Inspect the engine for potential hazards.

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

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

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

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

  See the Service Manual for repairs and foradjustments.

  i01933350

  Engine Starting

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

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

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

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

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

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

• 13Safety Section

  Engine Stopping

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

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

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

  i01032808

  Engine Stopping

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

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

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

  i01940471

  Electrical System

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

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

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

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

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

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

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

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

• 14Product Information SectionModel Views

  Product InformationSection

  Model Viewsi01933688

  Model View Illustrations

  g00988037Illustration 8

• 15Product Information Section

  Model Views

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

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

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

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

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

• 16Product Information SectionModel Views

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

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

• 17Product Information Section

  Model Views

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

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

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

• 18Product Information SectionModel Views

  i01933689

  Engine Description

  Table 1

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

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

  Table 2

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

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

  Engine Cooling and LubricationThe cooling system consists of the
  followingcomponents:

  Gear-driven centrifugal water pump

  Water temperature regulators which regulate theengine coolant
  temperature

  Gear-driven oil pump (gear type)

  Oil cooler

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

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

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

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

• 19Product Information Section

  Product Identification Information

  Product IdentificationInformation

  i01933733

  Engine Identification

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

  An example of an engine number is UEU090001H.

  UE _________________________________________Type of engine

  U __________________________Built in the United Kingdom

  0900001 ________________________Engine Serial Number

  H ____________________________________Year of Manufacture

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

  i01933737

  Serial Number Plate

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

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

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

  i01892045

  Reference Numbers

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

  Record for ReferenceEngine Model
  ______________________________________________

  Engine Serial No. __________________________________________

  Engine Low Idle rpm _____________________________________

  Engine Full Load rpm ____________________________________

  Primary Fuel Filter No. ___________________________________

  Water Separator Element No. __________________________

  Secondary Fuel Filter Element No. ____________________

  Lubrication Oil Filter Element No. _____________________

  Auxiliary Oil Filter Element No. _________________________

  Total Lubrication System Capacity ____________________

  Total Cooling System Capacity ________________________

  Air Cleaner Element No. _________________________________

  Fan Drive Belt No. ________________________________________

  Alternator Belt No. ________________________________________

  i01933748

  Emissions Certification Film

  A typical example is shown.

• 20Product Information SectionProduct Identification
  Information

  g01002325Illustration 13

• 21Operation Section

  Lifting and Storage

  Operation Section

  Lifting and Storagei01898037

  Engine Lifting

  g00103219Illustration 14

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

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

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

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

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

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

  i01942172

  Engine Storage

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

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

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

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

  Use the following guidelines :

  Completely clean the outside of the engine.

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

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

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

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

• 22Operation SectionLifting and Storage

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

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

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

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

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

  g00987502Illustration 15

  1. Ensure that the vehicle is on level ground.

  2. Remove the filler cap of the cooling system.

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

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

  5. Flush the cooling system with clean water.

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

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

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

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

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

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

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

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

  Induction System Remove the air filter assembly. If
  necessary,

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

  Exhaust System Remove the exhaust pipe. Spray 1762811

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

• 23Operation Section

  Lifting and Storage

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

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

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

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

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

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

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

• 24Operation SectionGauges and Indicators

  Gauges and Indicatorsi01930356

  Gauges and Indicators

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

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

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

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

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

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

  A lower oil pressure is normal at low idle. If the loadis stable
  and the gauge reading changes, performthe following procedure:

  1. Remove the load.

  2. Reduce engine speed to low idle.

  3. Check and maintain the oil level.

  Jacket Water Coolant Temperature Typical temperature range is 71
  to 96C(160 to 205F). The maximum allowable

  temperature with the pressurized cooling system at48 kPa (7 psi)
  is 110C (230F). Higher temperaturesmay occur under certain
  conditions. The watertemperature reading may vary according to
  load.The reading should never exceed the boiling pointfor the
  pressurized system that is being used.

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

  1. Reduce the load and the engine rpm.

  2. Inspect the cooling system for leaks.

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

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

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

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

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

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

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

  is in the on position.

  Service Hour Meter The gauge indicatesoperating time of the
  engine.

• 25Operation Section

  Engine Starting

  Engine Startingi01903008

  Before Starting Engine

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

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

  Inspect the cooling system hoses for cracks andfor loose
  clamps.

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

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

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

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

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

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

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

  Ensure that the areas around the rotating partsare clear.

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

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

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

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

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

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

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

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

• 26Operation SectionEngine Starting

  i01934161

  Starting the Engine

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

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

  Refer to the OEM Manual for your type of controls.

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

  2. Crank the engine. Start the engine.

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

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

  Table 3

  Preheat Times

  Temperature Preheat Time5 C (41 F) 10 seconds

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

  Continuous Preheat 60 seconds maximum

  5. Crank the engine. Start the engine.

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

  i01929012

  Starting with Jump StartCables

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

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

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

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

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

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

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

• 27Operation Section

  Engine Starting

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

  4. Start the engine.

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

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

  i01903609

  After Starting Engine

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

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

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

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

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

• 28Operation SectionEngine Operation

  Engine Operationi01903587

  Engine Operation

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

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

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

  i01934633

  Fuel Conservation Practices

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

  Avoid spilling fuel.

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

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

  Avoid unnecessary idling.

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

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

  Maintain a good electrical system.

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

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

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

  Ensure that the driven equipment is in goodworking order.

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

• 29Operation Section

  Engine Stopping

  Engine Stoppingi01935195

  Stopping the Engine

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

  Avoid accelerating the engine prior to shutting it down.

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

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

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

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

  i01903586

  Emergency Stopping

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

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

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

  i01935215

  After Stopping Engine

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

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

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

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

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

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

  Allow the engine to cool. Check the coolant level.

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

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

• 30Operation SectionCold Weather Operation

  Cold Weather Operationi01903584

  Cold Weather Operation

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

  The type of fuel that is used

  The viscosity of the oil

  The operation of the air inlet heater starting aid

  Optional Cold starting aid

  The purpose of this section will cover the
  followinginformation:

  Explain potential problems that are caused bycold weather
  operation.

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

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

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

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

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

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

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

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

  Keep all batteries fully charged and warm.

  Fill the fuel tank at the end of each shift.

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

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

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

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

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

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

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

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

• 31Operation Section

  Cold Weather Operation

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

  Startability is improved.

  Warm up time is reduced.

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

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

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

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

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

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

  Free operation of the valves is prevented.

  Valves become stuck.

  Pushrods are bent.

  Other damage to valve train components canresult.

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

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

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

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

• 32Operation SectionCold Weather Operation

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

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

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

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

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

  i01935225

  Fuel and the Effect from ColdWeather

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

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

  Group 1

  Group 2

  Group 3

  Special Fuels

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

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

  Special fuels include Biofuel.

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

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

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

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

  Glow plugs, which are standard equipment onall 800 Series
  engines

  Engine coolant heaters, which may be an OEMoption

  Fuel heaters, which may be an OEM option

  Fuel line insulation, which may be an OEM option

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

  A lower cloud point

  A lower pour point

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

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

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

• 33Operation Section

  Cold Weather Operation

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

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

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

  i01903588

  Fuel Related Components inCold Weather

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

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

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

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

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

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

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

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

• 34Maintenance SectionLubricant Specifications

  Maintenance Section

  Lubricant Specificationsi01903582

  Lubricant Information

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

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

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

  g00546535Illustration 16Typical API symbol

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

  Table 4

  API ClassificationsCurrent Obsolete

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

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

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

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

  i01903583

  Engine Oil

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

  Only use commercial oils that meet the
  followingclassifications:

  EMA DHD-1 multigrade oil (preferred oil)

  API CH-4 multigrade oil (preferred oil)

  ACEAE3

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

• 35Maintenance Section

  Lubricant Specifications

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

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

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

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

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

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

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

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

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

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

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

• 36Maintenance SectionLubricant Specifications

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

  the original TBN.

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

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

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

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

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

  Table 5

  Percentage of Sulfur in thefuel

  Oil change interval

  Lower than 0.5 Normal

  0.5 to 1.0 0.75 of normal

  Greater than 1.0 0.50 of normal

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

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

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

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

  Table 6

  Engine Oil ViscosityAmbient TemperatureEMA LRG-1

  API CH-4Viscosity Grade Minimum Maximum

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

  i01903738

  Synthetic Base Stock Oils

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

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

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

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

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

• 37Maintenance Section

  Lubricant Specifications

  i01903742

  Re-refined Base Stock Oils

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

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

  i01903752

  Cold Weather Lubricants

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

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

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

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

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

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

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

  i01904027

  Aftermarket Oil Additives

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

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

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

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

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

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

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

• 38Maintenance SectionFuel Specifications

  Fuel Specificationsi01904061

  Fuel Recommendations

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

  Cetane number__________________________45 minimum

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

  Density________________________0.835 to 0.855 Kg/liter

  Sulfur_______________________0.2% of mass, maximum

  Distillation___________________85% at 350 C (662 F)

  Lubricity______________________________460 micrometersmaximum
  wear scar on ISO 12156 — 1

  Cetane number

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

  Viscosity

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

  Sulfur

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

  Distillation

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

  Lubricity

  This is the capability of the fuel to prevent pumpwear.

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

  Group 1 (preferred fuels)

  Group 2 (permissible fuels)

  Group 3 (aviation kerosene fuels)

  Other fuels

  Group 1 (preferred fuels): SpecificationDERV to EN590

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

  Gas oil to BS2869 Class A2

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

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

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

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

  ASTM D975 — 91 Class 1D

  JP7, Mil T38219

  NATO F63

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

  Group 3 (aviation kerosene fuels): Specification

• 39Maintenance Section

  Fuel Specifications

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

  JP5 MIL T5624 (Avcat FSII, NATO F44

  JP8 T83133 (Avtur FSII, NATO F34

  Jet A

  Jet A1, NATO F35, XF63

  Low temperature fuels

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

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

  Lo

Each Perkins engine has its own Operation and Maintenance Manual (RETO / OMM). This provides all the necessary information so that your engine runs normally day after day. It contains detailed
information on regular maintenance intervals along with technical data and instructions.

Perkins issues Operation and Maintenance Manuals (OMMs) for each engine type. Each manual is divided into four sections, which cover:

• security,
• product information,
• exploitation,
• maintenance — this part contains information on the capacity of refueling containers, recommendations for liquids, schedules for maintenance intervals and maintenance procedures

Perkins is a subsidiary of Caterpillar and manufactures engines used in:

• agricultural machinery
• vehicles
• building
• electricity generation
• industry.

Example: 1206E-E66TA (G)

1206E-E66TA (G) 12 = Series. (12 = 1200 series)

1206E-E66TA (G) 06 = Number of cylinders

1206E-E66TA (G) (Emissions Compliancy) Emission Compliance

1206E-E66TA (G) (Electronic Fuel Injection) Electronic Injector

1206E-E66TA (G) Capacity in liters. (6.6 liter)

1206E-E66TA (G) Supercharging: T = Turbo, A = Air — air cooling, W = Water — water cooling.

1206E-E66TA (G) Generator Set Rating

Perkins 2806D-E18TA
Industrial Engine – PDF Service Manual

Perkins 2806F-E18TA
Industrial Engine – PDF Service Manual

PERKINS 4-108 SHOP
MANUAL

Perkins 400 Series
4016-E61TRS (Models 403C-11, 403C-15, 404C-22 and 404C-22T)

Perkins 4000 Series
(4006-23 TAG1A, TAG2A and TAG3A Inline diesel engine) 

Perkins 4000 Series Diesel
Engine – PDF Service Manual

Perkins 4000 Series Inline
diesel engine – PDF Service Manual

Perkins 4006 and 4008
Diesel engine – PDF Service Manual

Perkins 4006 TRS Gas and
4008 TRS Gas Industrial Engines – PDF Service Manua

Perkins 4006 TRS Gas and
4008 TRS GasIndustrial Engines Workshop Manual

Perkins 4006-23 and 4008-30
Industrial Engine – PDF Service Manual

Perkins 400A and 400D Industrial Engine – PDF Service Manual

Perkins 4012-46A Industrial
Engine – PDF Service Manual

Perkins 4016-61 TRG
Industrial Engine – PDF Service Manual

Perkins 4016-61TRS1 and
4016-61TRS2 Gas Engines – PDF Service Manual

Perkins 402D-403D-404D
Industrial Engine Disassembly and Assembly Manual

Perkins 402D-403D-404D
Industrial Engine PDF Service manual

Perkins 402F-05, 403F-07,
403F-11, and 403F-15 Industrial Engines – PDF Service Manual

Perkins 403F-15T, 404F-22
and 404F-22T Industrial Engines – PDF Service Manual.

Perkins 404A-22SG1 Gas
Industrial Engine – PDF Service Manual

Perkins 404F-E22T,
404F-E22TA and 403F-E17T Industrial Engines – PDF Service Manual

Perkins 800D Series
Industrial Engines – PDF Service Manual

Perkins 854E-E34TA and
854F-E34T Industrial Engine – PDF Service Manual

Perkins 854F-E34TA
Industrial Engine – PDF Service Manual

Perkins DIAG1300 User
manual.

Perkins Diesel Engine 4-154
Workshop Manual.

Perkins Engine Fault
Finding Guide.

Perkins Engine Number
Guide.

Perkins Phaser 4 – and
6-cylinder Workshop Manual

Perkins TIER2 DIESEL
ENGINES 1100 (VK) Workshop Manual

Perkins TPD1352 – PDF
Service Manual

The codes refer to the
model range of engines Perkins

Workshop Manual for Perkins
4.108, 4.107 and 4.99 diesel engines

Workshop Manual for Perkins
4.108M, 4.107M and 4.99M diesel engines