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User’s Handbook, TPD 1289E, Issue 2

iii

6.3544 Series

Contents

1 General information

Introduction  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1

Safety precautions  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2

How to care for your engine  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3

Engine preservation   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4

Parts and service   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6

POWERPART consumable products .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7

Engine identification  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8

Engine data   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9

2 Engine views

Introduction  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11

Location of engine parts (naturally aspirated engines)  ... ... ... ... ... ... ... ... ... ... ... ... ... . 11

Location of engine parts (turbocharged engines)  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 13

Location of engine parts (turbocharged engines with intercooler)  .. ... ... ... ... ... ... ... ... . 15

This document has been printed from SPI². Not for Resale

Summary of Contents for 6.3544 Series

Page 1: ...al use Publication TPD 1289E Issue 2 Proprietary information of Perkins Engines Company Limited all rights reserved The information is correct at the time of print Published in 1994 by Technical Publi...

Page 2: ...blication is divided into six chapters 1 General information 2 Engine views 3 Operation instructions 4 Preventive maintenance 5 Engine fluids 6 Fault diagnosis The following pages contain a detailed t...

Page 3: ...servation 4 Parts and service 6 POWERPART consumable products 7 Engine identification 8 Engine data 9 2 Engine views Introduction 11 Location of engine parts naturally aspirated engines 11 Location of...

Page 4: ...system 27 How to check the drive belt s 29 How to clean the gauze strainer of the fuel lift pump 30 Fuel pre filter 30 How to renew the filter element s of the fuel filter 31 Atomiser fault 32 How to...

Page 5: ...the valve tip clearances 41 5 Engine fluids Fuel specification 43 Lubricating oil specification 44 Coolant specification 45 6 Fault diagnosis Problems and possible causes 47 Code list of possible cau...

Page 6: ...vi This page is intentionally blank This document has been printed from SPI Not for Resale...

Page 7: ...ral applications More than fifty years of diesel production experience together with the latest technology have been applied to the manufacture of your engine to give you reliable and economic power T...

Page 8: ...an be discharged z Do not use salt water or any other coolant which can cause corrosion in the closed coolant circuit z Do not allow sparks or fire near the batteries especially when the batteries are...

Page 9: ...rtain maintenance intervals will have to be reduced Renew the filter elements and lubricating oil regularly in order to ensure that the inside of your engine remains clean Ensure that all adjustments...

Page 10: ...If protection against frost is not necessary and a corrosion inhibitor is to be used it is recommended that you consult the Service Department Perkins Power Sales and Service Limited Peterborough 7 Op...

Page 11: ...the starter motor with the engine stop control in the stop position until oil pressure is indicated Oil pressure can be indicated either by a gauge or when a low pressure warning light is extinguished...

Page 12: ...the Perkins POWER EXCHANGE system These will enable you to reduce the cost of certain repairs Service literature Workshop manuals and other service publications are available from your Perkins distrib...

Page 13: ...ne preservation on page 4 POWERPART Lay Up 3 Protects outside metal parts See Engine preservation on page 4 LOCTITE Chisel Allows easy and rapid removal of old gaskets and joints LOCTITE Repel Dries d...

Page 14: ...s of the engine number as indicated below The engine number is stamped on a label which is fastened to the auxiliary drive housing A1 Some engines also have the number stamped on the rear face of the...

Page 15: ...bore 98 43 mm 3 875 in Stroke 127 0 mm 5 00 in Compression ratio Engine types TW TX 16 0 1 Engine type TU 15 5 1 Cubic capacity 5 80 litres 354 in3 Firing order 1 5 3 6 2 4 Valve tip clearances cold...

Page 16: ...1 10 User s Handbook TPD 1289E Issue 2 6 3544 Series This document has been printed from SPI Not for Resale...

Page 17: ...necessarily match your engine specification Location of engine parts naturally aspirated engines Front and left side view of a naturally aspirated engine 1 Fuel filter 2 Fuel injection pump CAV 3 Flyw...

Page 18: ...ller cap for lubricating oil 11 Induction manifold 12 Alternator 13 Lubricating oil filter 14 Lubricating oil dipstick 15 Lubricating oil cooler 16 Lubricating oil sump 17 Starter motor 18 Flywheel 19...

Page 19: ...view of a turbocharged engine 1 Fuel filter 2 Compressor Option 3 Flywheel housing 4 Lubricating oil filter 5 Lubricating oil cooler 6 Crankshaft pulley 7 Drive belts 8 Fuel injection pump Bosch 9 Wat...

Page 20: ...ged engine 13 Filler cap for lubricating oil 14 Induction manifold 15 Alternator 16 Fuel lift pump 17 Lubricating oil dipstick 18 Lubricating oil sump 19 Starter motor 20 Flywheel 21 Turbocharger 22 E...

Page 21: ...ft side view of a turbocharged engine with intercooler 1 Filler cap for lubricating oil 2 Fuel filter 3 Flywheel housing 4 Lubricating oil cooler 5 Crankshaft pulley 6 Drive belts 7 Fuel injection pum...

Page 22: ...urbocharged engine with intercooler 12 Intercooler 13 Alternator 14 Lubricating oil dipstick 15 Turbocharger 16 Lubricating oil filter 17 Lubricating oil sump 18 Starter motor 19 Flywheel 20 Exhaust m...

Page 23: ...ction manifold and heat the induction air They are operated automatically when the starter motor is engaged When these devices are fitted the start procedure for a cold engine is the same as that give...

Page 24: ...djust the engine speed control to the quarter open position 3 Turn the start key to the HS or S position A to engage the starter motor 4 Allow the start key to return to the R position as soon as the...

Page 25: ...peed position 3 Turn the start key to the S position A to engage the starter motor Allow the key to return to the R position when the engine starts Then adjust the engine speed control to get an even...

Page 26: ...mum speed position 4 Turn the start key to the HS position in order to engage the starter motor Allow the start key to return to the R position when the engine starts Then adjust the engine speed cont...

Page 27: ...e engine starts release the start key to the R position and adjust the engine speed control to get an even idle speed 5 If the engine does not start in 30 seconds allow the start key to return to the...

Page 28: ...he starter motor 5 When the engine turns press the starting aid button for a maximum period of 2 seconds If the engine does not start after the first 2 second application keep the starter motor engage...

Page 29: ...ause this can damage the engine or transmission The warranty of the engine can be affected if the seals on the fuel injection pump are broken during the warranty period by a person who is not approved...

Page 30: ...pirated engine is to run at an altitude above 600 m 2 000 ft the fuel delivery can be changed to reduce fuel consumption and smoke Perkins can give the percentage of fuel reduction necessary if detail...

Page 31: ...must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine Caution For short distance operation with frequent stops the hours...

Page 32: ...lement z Renew the fuel filter elements fuel filter with twin element z Ensure that the atomisers are checked 2 z Ensure that the idle speed is checked and adjusted if it is necessary 2 z Check the am...

Page 33: ...from either side of the cylinder block A in order to drain the engine Note Ensure that the drain hole is not restricted 4 Open the tap or remove the drain plug at the bottom of the radiator in order...

Page 34: ...e cylinder block Fit the filler cap Close the radiator tap or connect the radiator hose Close the drain tap or fit the drain plug of the oil cooler If a water to air charge cooler is fitted fit the ve...

Page 35: ...check adjust the tension on the tighter belt How to adjust the belt tension 1 Loosen the pivot fasteners A1 of the alternator and the adjustment link fasteners A2 2 Change the position of the alterna...

Page 36: ...er 4 Assemble the lift pump Use a good joint and ensure that the lift pump body and the cover are fitted together correctly because leakage at this point will let air into the fuel system On engine ty...

Page 37: ...tom cover of the filter element and release the setscrew which is fitted through the filter head above the centre of each element 3 Lower the bottom cover of the filter B 4 Remove the element and disc...

Page 38: ...its seat washer A3 Remove the dust seal A4 and the spacer A1 and fit the spacer and a new dust seal onto the new atomiser 4 Put the new atomiser in position with its spacer new dust seal and a new sea...

Page 39: ...on bolt A2 or the straight connection A3 For fuel filters with a single element loosen the banjo connection bolt B1 2 Operate the priming lever on the fuel lift pump C until fuel free from air comes f...

Page 40: ...inue to operate the priming lever of the fuel lift pump until air free fuel comes from the vent screw on the governor cover Tighten the vent screw Bosch fuel injection pumps Clean the top of the fuel...

Page 41: ...plug and its O ring and tighten the plug to 34 Nm 25 Ibf ft 3 5 kgf m 3 If a lubricating oil cooler is fitted remove the oil drain plug if one is fitted refer to How to drain the cooling system on pa...

Page 42: ...and only Caution Do not use a strap wrench 7 Ensure that there is lubricating oil in the sump On turbocharged engines ensure that the engine will not start and operate the starter motor until oil pres...

Page 43: ...er 3 Seal the small hole A1 in the top cover of the breather valve with a water proof tape 4 Wash the breather valve in kerosene and dry it with low pressure air Remove the seal from the top of the br...

Page 44: ...must be drained at a suitable interval The container and element A1 must be cleaned with kerosene or with another suitable fluid Do not use gasolene Check that the seal A2 is not damaged and renew it...

Page 45: ...Certain air filters have automatic dust valves B1 through which dust is expelled from the filter The rubber dust valve must be kept clean Ensure that the sides of the valves close completely together...

Page 46: ...filter outlet or between the air filter and the induction manifold When the red warning indicator A1 is seen through the clear panel A2 after the engine has stopped the air filter element must be remo...

Page 47: ...has not closed completely Check the clearances of the valves of number 1 cylinder and adjust them if necessary 2 Set the valves of number 2 cylinder as indicated above for number 6 cylinder Then check...

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Page 49: ...uel A high ratio of light weight hydrocarbons can affect the combustion characteristics Low temperature fuels Special winter fuels may be available for engine operation at temperatures below 0 C These...

Page 50: ...l is used for the ambient temperature range in which the engine will run as shown in the chart below 1 Not recommended during the first 20 40 hours of operation nor for light load applications with na...

Page 51: ...hibiting engine coolant concentrate antifreeze Perkins POWERPART antifreeze exceeds the requirements of the above standards The quality of the antifreeze coolant must be checked at least once a year f...

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Page 53: ...36 37 38 39 40 42 43 44 63 Black exhaust smoke 11 13 15 17 19 21 22 34 36 37 38 39 40 42 43 44 61 63 Blue or white exhaust smoke 4 15 21 23 36 37 38 39 42 44 45 52 58 62 The pressure of the lubricatin...

Page 54: ...ow 22 Incorrect valve tip clearances 23 Too much oil or oil of a wrong specification is used in wet type air cleaner 24 Not enough lubricating oil in sump 25 Defective gauge 26 Dirty lubricating oil f...

Page 55: ...d correctly 55 Fault in thermostat or thermostat is of an incorrect type 56 Restriction in coolant passages 57 Fault in water pump 58 Valve stem seal is damaged if there is one fitted 59 Restriction i...

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