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i04103075

Maintenance
Recommendations

Welding

 

on

 

Engines

 

with

 

Electronic

 

Controls

 

NOTICE

Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.

Proper welding procedures are necessary in order to
avoid damage to the engines ECM, sensors, and
associated components. When possible, remove the
component from the unit and then weld the
component. If removal of the component is not
possible, the following procedure must be followed
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.

NOTICE

Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding
can cause damage to the drive train bearings, hy-
draulic components, electrical components, and oth-

er components.

Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.

Note:

Perform the welding in areas that are free from

explosive hazards.

1.

Stop the engine. Turn the switched power to the

OFF position.

2.

Ensure that the fuel supply to the engine is turned

off.

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

• Electronically controlled valves

• Relays

• Aftertreatment ID module

NOTICE

Do not use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.

Illustration 31

g01075639

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

SEBU8172-04

67

Maintenance Section

Maintenance Recommendations

Summary of Contents for 1104D

Page 1: ...Operation and Maintenance Manual 1104D Engine NH Engine NJ Engine SEBU8172 04 en us January 2021 ...

Page 2: ...ormation 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 informatio...

Page 3: ...lectrical System 18 Engine Electronics 19 Product Information Section Model Views 20 Product Identification Information 25 Operation Section Lifting and Storage 27 Gauges and Indicators 30 Features and Controls 31 Engine Diagnostics 38 Engine Starting 42 Engine Operation 44 Engine Stopping 45 Cold Weather Operation 47 Maintenance Section Refill Capacities 51 Maintenance Recommendations 67 Maintena...

Page 4: ...s manual Whenever a question arises regarding your engine or this manual please consult with your Perkins dealer or your Perkins distributor for the latest available information Safety This safety section lists basic safety precautions In addition this section identifies hazardous warning situations Read and understand the basic precautions listed in the safety section before operating or performi...

Page 5: ...r the engine as a convenient reminder Perkins also recommends that a maintenance record be maintained as part of the permanent record of the engine Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Man...

Page 6: ...the warning signs The warning signs that are loosened could drop off of the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is replaced install a new warning sign on the replacement part Your Perkins dealer or your distributor can provide new warning signs 1 Universal Warning Do not operate or work on this equipment unless you h...

Page 7: ...ct 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 SEBU8172 04 7 Safety Section Safety Messages ...

Page 8: ...label for the Hand High Pressure 2 is located on the top of the fuel manifold Refer to illustration 4 3 Ether Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury Illustration 5 g01154809 Typical example 8 SEBU8172 04 Safety Section Safety Messages ...

Page 9: ...ion Refer to the OEM information for the procedure for placing the equipment in the servicing position Do not attempt any repairs that are not understood Use the proper tools Replace any equipment that is damaged or repair the equipment For initial start up of a new engine or for starting an engine that has been serviced make provisions to stop the engine if an overspeed occurs The stopping of the...

Page 10: ...ge Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the engine Make provision to collect the fluid with a suitable container before any compartment is opened or before any component is disassembled Only use the tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids Only us...

Page 11: ...es when handling the equipment or parts Perkins also recommends the following Wear appropriate Personal Protective Equipment PPE Wash your hands and face with soap and water prior to eating drinking or smoking and also during rest room breaks to prevent ingestion of any yellow powder Never use compressed air for cleaning areas suspected of containing hexavalent chromium Avoid brushing grinding or ...

Page 12: ... items are disconnected Coolant When the engine is at operating temperature the engine coolant is hot The coolant is also under pressure The radiator and all lines to the heaters or to the engine contain hot coolant Any contact with hot coolant or with steam can cause severe burns Allow cooling system components to cool before the cooling system is drained Check that the coolant level after the en...

Page 13: ...debris from the engine Do not allow any flammable combustible materials or conductive materials to accumulate on the engine 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 shie...

Page 14: ...ydrometer Incorrect jumper cable connections can cause an explosion that can result in injury Refer to the Operation Section of this manual for specific instructions Do not charge a frozen battery Charging a frozen battery may cause an explosion The batteries must be kept clean The covers if equipped must be kept on the cells Use the recommended cables connections and battery box covers when the e...

Page 15: ...e objects are struck ensure that no one will be injured by flying debris i02235492 Mounting and Dismounting Inspect the steps the handholds and the work area before mounting the engine Keep these items clean and keep these items in good repair Mount the engine and dismount the engine only at locations that have steps and or handholds Do not climb on the engine and do not jump off the engine Face t...

Page 16: ...h pressure fuel lines Do not bend or strike the high pressure fuel lines Deformation or damage of the high pressure fuel lines may cause a point of weakness and potential failure Do not check the high pressure fuel lines with the engine or the starting motor in operation After the engine has stopped allow 60 seconds to pass in order to allow the pressure to be purged before any service or repair i...

Page 17: ...pped All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures To help prevent an accident that is caused by parts in rotation work around the parts carefully Do not bypass the automatic shutoff circuits Do not disable the automatic shutoff circuits The circuits are provided in order to help prevent personal injury The ci...

Page 18: ... the engine i02234878 Electrical System Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating A spark can cause the combustible gases that are produced by some batteries to ignite To help prevent sparks from igniting combustible gases that are produced by some batteries the negative cable should be connected last from the external ...

Page 19: ...o 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 ...

Page 20: ...e following model views show typical features of the engine Due to individual applications your engine may appear different from the illustrations Illustration 17 g01425089 The 1104D NJ engine is turbocharged and aftercooled 20 SEBU8172 04 Product Information Section Model Views ...

Page 21: ...ye 2 Water outlet 3 Rear lifting eye 4 Fuel manifold rail 5 Electronic control module 6 Secondary fuel filter 7 Water pump 8 Oil Filler 9 Oil gauge 10 Oil sampling valve 11 Oil filter 12 Crankshaft pulley 13 Drive Belt 14 Belt tensioner SEBU8172 04 21 Product Information Section Model View Illustrations ...

Page 22: ... applications machine and industrial mobile equipment The engine is available in the following type of aspiration Turbocharged Turbocharged aftercooled In line 4 cylinder Engine Specifications 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 Emissio...

Page 23: ...ngine features refer to the Operation and Maintenance Manual Features and Controls topic Operation Section Engine Diagnostics The engine has built in diagnostics in order to ensure that the engine systems are functioning correctly The operator will be alerted to the condition by a Stop or Warning lamp Under certain conditions the engine horsepower and the vehicle speed may be limited The electroni...

Page 24: ... maintenance recommendations Engine performance and efficiency also depend on the use of recommended fuels lubrication oils and coolants Refer to this Operation and Maintenance Manual Maintenance Interval Schedule for more information on maintenance items 24 SEBU8172 04 Product Information Section Engine Description ...

Page 25: ...ese numbers can be read by using the Electronic Service Tool Serial Number Plate 1 The engine serial number plate is located on the left side of the cylinder block to the rear of the engine Illustration 22 g01094203 Serial number plate i02164876 Reference Numbers Information for the following items may be needed to order parts Locate the information for your engine Record the information in the ap...

Page 26: ...Fan Drive Belt Alternator Belt i02861254 Emissions Certification Film Illustration 23 g01440937 Typical example 26 SEBU8172 04 Product Information Section Emissions Certification Film ...

Page 27: ...ents are damaged 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 Some removals require lifting the fixtures to obtain correct balance and safety To remove the engine ONLY use the lifting eyes t...

Page 28: ... on the cylinder walls Rust on the cylinder walls will cause increased engine wear and a reduction in engine service life Perkins are not responsible for damage which may occur when an engine is in storage after a period in service Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods If an engine is out of operation and if use of the engin...

Page 29: ...l Mark on the engine oil level gauge with new clean lubricating oil Add 1762811 POWERPART Lay Up 2 to the oil in order to protect the engine against corrosion If 1762811 POWERPART Lay Up 2 is not available use a preservative of the correct specification instead of the lubricating oil If a preservative is used this must be drained completely at the end of the storage period and the oil pan must be ...

Page 30: ...ad is stable and the gauge reading changes perform the following procedure 1 Remove the load 2 Stop the engine 3 Check and maintain the oil level Jacket Water Coolant Temperature Typical temperature range is 83 to 95 C 181 4 to 171 F The maximum allowable temperature at sea level with the pressurized cooling system at 48 kPa 7 psi is 103 C 217 4 F Higher temperatures may occur under certain condit...

Page 31: ...m If the Shutdown mode has been selected and the warning indicator activates engine shutdown may take as little as 20 seconds from the time the warning indicator is activated Depending on the application special precautions should be taken to avoid personal injury The engine can be re started following shutdown for emergency ma neuvers if necessary NOTICE The Engine Monitoring System is not a guar...

Page 32: ... a shutdown of the engine occurs The engine can be restarted after a shutdown for use in an emergency A shutdown of the engine may occur in as little as 20 seconds The engine can be restarted after a shutdown for use in an emergency However the cause of the initial shutdown may still exist The engine may shut down again in as little as 20 seconds If there is a signal for low oil pressure or for co...

Page 33: ...t air temperature sensor 4 Fuel pressure sensor 5 Electronic control module 6 Primary position sensor 7 Secondary position sensor 8 Engine oil pressure sensor Illustration 28 shows the sensors and the ECM in position on the engine SEBU8172 04 33 Operation Section Sensors and Electrical Components ...

Page 34: ...grammable Monitoring System PMS The Programmable Monitoring System determines the level of action that is taken by the Electronic Control Module ECM in response to a condition that can damage the engine These conditions are identified by the ECM from the signals that are produced from the following sensors Coolant Temperature Sensor Intake manifold Air Temperature Sensor Intake manifold Pressure S...

Page 35: ...the manifold A signal is sent to the ECM 5 Fuel Pressure Sensor 4 The fuel pressure sensor measures the fuel pressure in the fuel manifold A signal is sent to the ECM 5 Electronic Control Module 5 The ECM is the control computer of the engine The ECM provides power to the electronics The ECM monitors data that is input from the sensors of the engine The ECM acts as a governor in order to control t...

Page 36: ... selected the ECM 5 will derate the engine power The engine horsepower will be limited Failure of the Engine Oil Pressure Sensor The ECM 5 will detect failure of the engine oil pressure sensor The diagnostic lamp warns the user about the status of the engine oil pressure sensor The engine oil pressure related strategies will be disabled in the event of a failure of the engine oil pressure sensor A...

Page 37: ...ned switch This switch can shut down the engine remotely Water in fuel switch This switch checks for water in the primary fuel filter when the engine is operating Note The sensing element of the coolant temperature switch must be submerged in coolant in order to operate Engines may be equipped with alarms in order to alert the operator when undesirable operating conditions occur NOTICE When an ala...

Page 38: ...ctronic Service Tools for more information i02855276 Diagnostic Flash Code Retrieval Diagnostic Lamp Use the DIAGNOSTIC Lamp or an electronic service tool to determine the diagnostic flash code Use the following procedure to retrieve the flash codes if the engine is equipped with a DIAGNOSTIC lamp 1 Turn the keyswitch ON OFF two times within 3 seconds A flashing YELLOW lamp indicates a 3 digit cod...

Page 39: ...ng Calibration Fault X X 144 Engine Operation Mode Selector Switch Fault X X 151 High Air Filter Restriction X X 154 Throttle Position sensor Fault X X 155 Secondary Throttle Posi tion sensor Fault X X 157 Oil Pressure Sensor Fault 5 X X X X X 159 Fuel Rail Pressure Sen sor Fault X X 162 High Pressure Fuel Pump Fault X X X 168 Coolant Temperature Sensor Fault X X X 169 Low Engine Coolant X X 177 W...

Page 40: ...ice tool The active codes that have been logged will be cleared when the fault has been rectified or the fault is no longer active The following logged faults can not be cleared from the memory of the ECM without using a factory password Overspeed low engine oil pressure and high engine coolant temperature i02651197 Engine Operation with Active Diagnostic Codes If a diagnostic lamp illuminates dur...

Page 41: ...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 SEBU8172 04 41 Operation Section Engine ...

Page 42: ... module ECM will control the engine speed during start up Starting the Engine 1 Disengage any equipment that is driven by the engine 2 Turn the keyswitch to the RUN position Leave the 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 extinguished turn the keyswitch to the START position in order to engage the ele...

Page 43: ...t be replaced or charged to the proper voltage with a battery charger after the engine is stopped Many batteries which are considered unusable are still rechargeable Refer to Operation and Maintenance Manual Battery Replace and Testing and Adjusting Manual Battery Test i02330138 After Starting Engine Note In ambient temperatures from 0 to 60 C 32 to 140 F the warm up time is approximately three mi...

Page 44: ... 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 Avoid unnece...

Page 45: ...e the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan 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 you must wait for 60 seconds in order to a...

Page 46: ...correct corrosion protection Add the correct coolant water mixture if necessary Perform all required periodic maintenance on all driven equipment This maintenance is outlined in the instructions from the OEM 46 SEBU8172 04 Operation Section After Stopping Engine ...

Page 47: ...r Cold Weather Operation If the engine will start operate the engine until a minimum operating temperature of 81 C 177 8 F is achieved Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdown This means that an engine can be shut down for a period of t...

Page 48: ...dations for Coolant Warm Up Warm up an engine that has cooled below normal operating temperatures due to inactivity The warm up should be performed before the engine is returned to full operation During operation in very cold temperature conditions damage to engine valve mechanisms can result from engine operation for short intervals This action can happen if the engine is started and the engine i...

Page 49: ...nt i07818744 Fuel and the Effect from Cold Weather Note Only use grades of fuel that are recommended by Perkins Refer to this Operation and Maintenance Manual Fluid Recommendations Properties of the diesel fuel can have a significant effect on the engine cold start capability It is critical that the low temperature properties of diesel fuel are acceptable for the minimum ambient temperature the en...

Page 50: ... and or sediment from being pumped from the fuel storage tank and into the engine fuel tank Fuel Filters A primary fuel filter is installed between the fuel tank and the engine fuel inlet After you change the fuel filter always prime the fuel system in order to remove air bubbles from the fuel system Refer to the Operation and Maintenance Manual in the Maintenance Section for more information on p...

Page 51: ...ers will require additional 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 t...

Page 52: ... use of this document you agree that Perkins Engines Company Limited is not responsible for errors or omissions NOTICE These recommendations are subject to change with out notice Contact your local Perkins distributor for the most up to date recommendations Diesel Fuel Requirements Satisfactory engine performance is dependent on the use of a good quality fuel The use of a good quality fuel will gi...

Page 53: ...per 100 mL maximum D381 ISO 6246 Lubricity corrected wear scar diameter at 60 C 140 F 7 mm 0 52 maximum D6079 ISO 12156 1 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 This specification includes the requirements for Low Sulfur Diesel LSD LSD fuel will have ...

Page 54: ...ing conditions A higher cetane value may be required for operations at high altitudes or in cold weather operations Fuel with a low cetane number can be the root cause of problems during cold start Viscosity Viscosity is the property of a liquid of offering resistance to shear or flow Viscosity decreases with increasing temperature This decrease in viscosity follows a logarithmic relationship for ...

Page 55: ...at 60 C 140 F Refer to ISO 12156 part 1 and CEC document F06 A 96 for the test method Lubricity wear scar diameter of 0 52 mm 0 0205 inch MUST NOT be exceeded The fuel lubricity test must be performed on a HFRR operated at 60 C 140 F Refer to ISO 12156 1 Fuel additives can enhance the lubricity of a fuel Contact your fuel supplier for those circumstances when fuel additives are required Your fuel ...

Page 56: ... SME is the most common biodiesel in the United States This biodiesel is derived from soybean oil Soybean oil or rapeseed oil are the primary feedstocks These fuels are together known as Fatty Acid Methyl Esters FAME Raw pressed vegetable oils are NOTacceptable for use as a fuel in any concentration in compression engines Without esterification these oils gel in the crankcase and the fuel tank The...

Page 57: ...l to a maximum of B5 Examples of applications that should limit the use of biodiesel are the following Standby Generator sets and certain emergency vehicles Biodiesel is an excellent medium for microbial contamination and growth Microbial contamination and growth can cause corrosion in the fuel system and premature plugging of the fuel filter The use of conventionalanti microbial additives and the...

Page 58: ...ated in table 6 i02865363 Fluid Recommendations General Lubricant Information Because of government regulations regarding the certification of exhaust emissions from the engine the lubricant recommendations must be followed EMA Engine Manufacturers Association API American Petroleum Institute SAE Society Of Automotive Engineers Inc EMA Guidelines The Engine Manufacturers Association Recommended Gu...

Page 59: ...mize the life of the oil These oil change interval programs are based on oil analysis DHD 1 oils are recommended for conditions that demand a premium oil Your Perkins distributor has the specific guidelines for optimizing oil change intervals API CH 4 API CH 4 oils were developed in order to meet the requirements of the new high performance diesel engines Also the oil was designed to meet the requ...

Page 60: ...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 Recommendations for Direct Injection DI Diesel Engines The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start up and the maximum ambient temperature during engine operation Refer to Table 11 minimum temperature in order to...

Page 61: ...aximum service life or rated performance Fully formulated finished oils consist of base oils and of commercial additive packages These additive packages are blended into the base oils at precise percentages in order to help provide finished oils with performance characteristics that meet industry standards There are no industry standard tests that evaluate the performance or the compatibility of a...

Page 62: ...gulators Many engine failures are related to the cooling system The following problems are related to cooling system failures Overheating leakage of the water pump and plugged radiators or heat exchangers These failures can be avoided with correct cooling system maintenance Cooling system maintenance is as important as maintenance of the fuel system and the lubrication system Quality of the coolan...

Page 63: ...nt measure the specific gravity of the coolant Coolant Recommendations ELC Extended Life Coolant SCA Supplement Coolant Additive ASTM American Society for Testing and Materials The following two coolants are used in Perkins diesel engines Preferred Perkins ELC Acceptable A commercial heavy duty antifreeze that meets ASTM D4985 specifications NOTICE Do not use a commercial coolant antifreeze that o...

Page 64: ...ife Coolant ELC Do not use standard supplemental coolant additive SCA When using Perkins ELC do not use standard SCA s or SCA filters ELC Cooling System Cleaning Note If the cooling system is already using ELC cleaning agents are not required to be used at the specified coolant change interval Cleaning agents are only required if the system has been contaminated by the addition of some other type ...

Page 65: ...percent Maintain the system as a conventional Heavy Duty Coolant Treat the system with an SCA Change the coolant at the interval that is recommended for the conventional Heavy Duty Coolant Commercial Heavy Duty Antifreeze and SCA NOTICE Commercial Heavy Duty Coolant which contains Amine as part of the corrision protection system must not be used NOTICE Never operate an engine without water tempera...

Page 66: ...essary Table 19 Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance V 0 014 X V is the total volume of the cooling system X is the amount of SCA that is required Table 20 is an example for using the equation that is in Table 19 Table 20 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance Total Volume of the Cooling System V Multiplication Factor A...

Page 67: ...ose as possible to the weld This will help reduce the pos sibility of damage Note Perform the welding in areas that are free from explosive hazards 1 Stop the engine Turn the switched power to the OFF position 2 Ensure that the fuel supply to the engine is turned off 3 Disconnect the negative battery cable from the battery If a battery disconnect switch is provided open the switch 4 Disconnect all...

Page 68: ...rical 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 7 Use standard welding practices to weld the materials 68 SEBU8172 04 Maint...

Page 69: ...l and Filter Change 88 Initial 500 Service Hours Engine Valve Lash Inspect Adjust 88 Every 500 Service Hours Fan Clearance Check 89 V Belts Inspect Adjust Replace 102 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check 73 Cooling System Supplemental Coolant Additive SCA Test Add 79 Crankcase Breather Canister Replace 80 Engine Air Cleaner Element Dual Element Clean Replace 81 Engine ...

Page 70: ...ice Hours or 2 Years Cooling System Coolant Commercial Heavy Duty Change 74 Every 4000 Service Hours Aftercooler Core Clean Test 71 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 76 Commissioning Fan Clearance Check 89 70 SEBU8172 04 Maintenance Section Maintenance Interval Schedule ...

Page 71: ...y can result without following prop er procedure When using pressure air wear a protective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 8 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 9 Inspect the core in order to ensure cleanliness Pressure test the core If necessary rep...

Page 72: ...ine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge i02491869 Alternator Belt Inspect Adjust Replace Poly V Belt Inspection To maximize the engine performance inspect the belt 1 for wear and for cracking Replace the belt if the belt is worn or damag...

Page 73: ...rged the ammeter reading should be very near zero when the engine is in operation All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If di...

Page 74: ... Coolant Commercial Heavy Duty Change 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 contain ers before opening any compartment or disassem bling any component containing fluids Dispose of all fluids according to Local regulations and mandates NOT...

Page 75: ...relieve any pressure Remove the cooling system filler cap Open the drain cock or 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 Close the drain cock or install the drain plug on the engine Close the drain cock or install the drain plug on the radiator NOTICE Do not fill the c...

Page 76: ...hortened 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 coolant is contaminated The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cl...

Page 77: ...tor Allow the water to drain Flush the cooling system with clean water Fill 1 Close the drain cock or 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 to avoid air locks Cooling system air locks may result in engine damage 2 Fill the cooling system with Extended Life Coola...

Page 78: ...ing system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pressure 2 Loosen filler cap slowly in order to relieve any pressure Remove the filler cap 3 Pour the correct coolant mixture into the tank Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations for information on the correct mixture and type of coolant Refer to the Ope...

Page 79: ...lemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high tempera ture components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and or accelerated w...

Page 80: ... N m 8 lb ft Do not overtighten the canister 4 Remove the container Dispose of the old canister and any split oil in a safe place i02151646 Driven Equipment Check Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment Inspection Adjustment Lubrication Other maintenance recommendations Perform any maintenance for the driven equipme...

Page 81: ...ements for your application Check the precleaner if equipped and the dust bowl daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating in dirty conditions may require more frequent service of the air cleaner element The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replac...

Page 82: ...ir cleaner elements for damage to the pleats the seals the gaskets and the outer cover Discard any damaged air cleaner element Two methods may be used in order to clean the primary air cleaner element pressurized air Vacuum cleaning Pressurized Air Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a protective f...

Page 83: ...red 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 r...

Page 84: ...d the correct bolt torque Inspect the engine mounts for deterioration and for correct bolt torque Excessive 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 When the engine mounts are ...

Page 85: ... engine operation Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin In order to help obtain the most accurate analysis record the following information before an oil sample is taken The date of the sample Engine model Engine number Service hours on the engine The number of hours that have accumulated s...

Page 86: ...l has drained the oil drain plugs should be cleaned and installed If necessary replace the O ring seal Tighten the drain plug to 34 N m 25 lb ft Replace the Oil Filter NOTICE Perkins oil filters are manufactured to Perkins specifi cations Use of an oil filter that is not recommended by Perkins could result in severe damage to the en gine bearings crankshaft etc as a result of the larg er waste par...

Page 87: ...ed horizontally Refer to illustration 50 This type of oil filter assembly can be drained before the filter is removed Start at step 1 in order to remove the oil filter and install the oil filter Fill the Oil Pan 1 Remove the oil filler cap Refer to this Operation and Maintenance Manual Fluid Recommendations for more information on suitable oils Fill the oil pan with the correct amount of new engin...

Page 88: ... maintenance schedule in order to help provide maximum engine life NOTICE Only qualified service personel should perform this maintenance Refer to the Service Manual or your au thorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure Operation of Perkins engines with incorrect valve lash can reduce engine efficiency and also reduce engine component life ...

Page 89: ...tration 53 g01363916 3 Tighten the bolts to the following torque 40 N m 29 5 lb ft i02683336 Fan Clearance Check There are different types of cooling systems Refer to the OEM for information on clearance for the fan Ensure that the engine is stopped Ensure that the cooling system is full The clearance between the cover 1 and the fan 2 will require checking The gap A between the edge of the cover a...

Page 90: ...re adjustments and repairs are performed Note Refer to Systems Operation Testing and Adjusting Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training NOTICE Do not crank the engine continuou...

Page 91: ...s may cause personal injury or death After the engine has stopped you must wait for 60 seconds 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 ...

Page 92: ...ass bowl 6 Hold glass bowl 3 and remove screw 2 Remove glass bowl 3 from canister 4 7 Use a suitable tool in order to remove canister 4 Discard the old seals 5 and 6 and the canister in a safe place 8 Clean glass bowl 3 Illustration 57 g01259366 Typical example 9 Install the new canister Do not use a tool in order to install the canister Tighten the canister by hand 10 Install new O ring seal 5 on...

Page 93: ...erformed 1 Turn the fuel supply valve if equipped to the OFF position before performing this maintenance 2 Place a suitable container under the water separator in order to catch any fuel that might spill Clean up any spilled fuel Clean the outside of the water separator Illustration 58 g01429124 3 Install a suitable tube onto drain 1 Open drain 1 Allow the fluid to drain into the container Remove ...

Page 94: ...ighten the canister correctly 9 Remove cap 8 from the threaded end of the new canister and remove new O ring seal 7 Install the new O ring seal into bowl 3 10 Lubricate O ring seal 7 with clean engine oil Install the bowl onto the new canister Tighten the bowl to 15 N m 11 lb ft 11 If equipped install the wiring harness to the sensor Open the fuel supply valve 12 Remove the container and dispose o...

Page 95: ... 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 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 enter...

Page 96: ... of cleanliness that must be observed during ALL work on the fuel system NOTICE Ensure that the engine is stopped before any servic ing or repair is performed This fuel filter can be identified by the six drain holes in the filter Refer to illustration 64 Illustration 64 g01429525 Typical example After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be pu...

Page 97: ... Clean up fuel spills immediately Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system NOTICE Ensure that the engine is stopped before any servic ing or repair is performed Illustration 66 g01429532 This fuel filter can be identified by the 12 drain holes in...

Page 98: ...r disassem bling any component containing fluids Dispose of all fluids according to local regulations and mandates Fuel Tank 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 Water can be introduced into the fuel tank when the fuel tank is being filled Condensation occurs during the heating and cooling of...

Page 99: ...damaged or leaking Outer covering that is chafed or cut Exposed wire that is used for reinforcement Outer covering that is ballooning locally Flexible part of the hose that is kinked or crushed Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp...

Page 100: ...arallel with the radiator tube assembly This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with ...

Page 101: ...ng outside the intended application Incorrect Maintenance Procedures Extending the maintenance intervals Failure to use recommended fuel lubricants and coolant antifreeze i07888480 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 ...

Page 102: ...e is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the intake air clogged air filters which causes the turbocharger to slobber 4 Inspect the bore of the housing of the turbine outlet for corrosion 5 Fasten the air intake pipe and the exhaust o...

Page 103: ... order to increase or decrease the belt tension Tighten the nut 2 and the bolt 3 to 22 N m 16 lb ft 1 Replace Refer to Disassembly and Assembly manual V Belts Remove and Install for more information i03577563 Walk Around Inspection Inspect the Tube of the Crankcase Breather Illustration 71 g01905095 Inspect the breather tube 1 for damage Ensure that the outlet 2 is clean and free from any obstruct...

Page 104: ...s replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break High Pressure Fuel Lines 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 ma...

Page 105: ...re Other potential damage to the engine Illustration 72 g01249453 1 Weep hole Note The water pump seal is lubricated by the coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and parts contract Visually inspect the water pump for leaks The water pump is not a serviceable item In order to install a new water pump refer to the Disassembly and A...

Page 106: ...seous emission standards that are prescribed by the law at the time of manufacture This engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or distributor to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty 106 SEBU8172 04 Warranty Section Warranty Information ...

Page 107: ...e SCA If Necessary 79 Test for SCA Concentration 79 Crankcase Breather Canister Replace 80 Crushing Prevention and Cutting Prevention 15 D Diagnostic Flash Code Retrieval 38 Diagnostic Lamp 38 Diagnostic Lamp 38 Driven Equipment Check 80 E Electrical System 18 Grounding Practices 18 Emergency Stopping 45 Emissions Certification Film 26 Emissions Warranty Information 106 Engine Clean 80 Engine Air ...

Page 108: ... Conservation Practices 44 Fuel Related Components in Cold Weather 50 Fuel Filters 50 Fuel Heaters 50 Fuel Tanks 50 Fuel System Prime 90 Hand Fuel Priming Pump 91 Fuel System Primary Filter Water Separator Element Replace 91 Type One Filter 91 Type Two Filter 92 Fuel System Primary Filter Water Separator Drain 95 Primary Filter with a Vent Screw 95 Fuel System Secondary Filter Replace 96 Type One ...

Page 109: ...le 5 35 Engine Oil Pressure Sensor 8 36 Failure of Sensors 34 Fuel Pressure Sensor 4 35 Intake Manifold Air Temperature Sensor 2 35 Intake Manifold Pressure Sensor 3 35 Primary Speed Timing Sensor 6 35 Programmable Monitoring System PMS 34 Secondary Speed Timing Sensor 7 36 Sensor Locations 32 Severe Service Application Check 100 Environmental Factors 101 Incorrect Maintenance Procedures 101 Incor...

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Page 111: ...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 Contact Phone Number Hours Sales Parts Service ...

Page 112: ...SEBU8172 2021 Perkins Engines Company Limited All Rights Reserved 112 January 2021 ...

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