Operation and Maintenance Manual: 4012-46A Industrial Engine

SEBU8191-01 November 2011
Operation and Maintenance Manual

4012-46A Industrial Engine
S12 (Engine)
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication. Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this product Perkins recommends using Perkins replacement parts. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.
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3 Table of Contents
Table of Contents
Foreword ................................................................. 4
Index Section
Index ..................................................................... 74
Safety Section
Safety Messages .................................................... 5 General Hazard Information ................................... 5 Burn Prevention ...................................................... 7 Fire Prevention and Explosion Prevention .............. 7 Crushing Prevention and Cutting Prevention .......... 9 Mounting and Dismounting ..................................... 9 Before Starting Engine .......................................... 10 Engine Starting ..................................................... 10 Engine Stopping ................................................... 10 Electrical System ................................................... 11 Engine Electronics ................................................. 11
Product Information Section

General Information .............................................. 12 Model Views ......................................................... 13 Product Identication Information ........................ 17
Operation Section
Lifting and Storage ................................................ 19 Features and Controls .......................................... 20 Engine Starting ..................................................... 23 Engine Operation .................................................. 25 Engine Stopping ................................................... 26
Maintenance Section
Rell Capacities .................................................... 27 Maintenance Interval Schedule ............................ 40
Warranty Section
Warranty Information ............................................ 73
4 Foreword
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Foreword
Literature Information
This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information. English is the primary language for all Perkins publications. The English used facilitates translation and consistency. Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Perkins dealer or your Perkins distributor for the latest available information.
Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specied in the Maintenance Interval Schedule may be necessary. The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the original requirement. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine's permanent record. Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.
Safety
This safety section lists basic safety precautions. In addition, this section identies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.
Overhaul
Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your Perkins distributor offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options.
Operation
Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efciently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities. The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.
California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
Maintenance
The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.
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5 Safety Section Safety Messages
Safety Section
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(2) Hot Coolant
Safety Messages
There may be several specic warning signs on your engine. The exact location and a description of the warning signs are reviewed in this section. Please become familiar with all warning signs. Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning signs. The warning signs that are loosened could drop off 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.
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loose the cap slowly to relieve the pressure.
(1) Universal Warning
Illustration 2
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Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death.
General Hazard Information
Illustration 3
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Illustration 1
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Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment.
6 Safety Section General Hazard Information
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When pressurized air and/or water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).
Fluid Penetration
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Illustration 4
Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic uid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly. Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure.
Wear a hard hat, protective glasses, and other protective equipment, as required. Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. Make sure that all protective guards and all covers are secured in place on the engine. Keep the engine free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps. Never put maintenance uids into glass containers. Drain all liquids into a suitable container. Obey all local regulations for the disposal of liquids. Use all cleaning solutions with care. Report all necessary repairs. Do not allow unauthorized personnel on the equipment. Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs. Perform maintenance on the engine with the equipment in the servicing position. Refer to the OEM information for the procedure for placing the equipment in the servicing position.
Illustration 5
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Always use a board or cardboard when you check for a leak. Leaking uid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If uid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
Pressure Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury. The direct application of pressurized air or pressurized water to the body could result in personal injury.
Containing Fluid Spillage

Care must be taken in order to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Make provision to collect the uid with a suitable container before any compartment is opened or before any component is disassembled.
Only use the tools that are suitable for collecting
uids and equipment that is suitable for collecting uids.
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7 Safety Section Burn Prevention
Only use the tools that are suitable for containing
uids and equipment that is suitable for containing uids.
Oils
Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin.
Obey all local regulations for the disposal of liquids.

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Burn Prevention
Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine.
Batteries
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.
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Contact with high pressure fuel may cause uid penetration and burn hazards. High pressure fuel spray may cause a re hazard. Failure to follow these inspection, maintenance and service instructions 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. Allow the pressure to be purged in the air system, in the hydraulic system, in the lubrication system, or in the cooling system before any lines, ttings or related items are disconnected.
Fire Prevention and Explosion Prevention
Coolant
When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. Check the coolant level after the engine has stopped and the engine has been allowed to cool. Ensure that the ller cap is cool before removing the ller cap. The ller cap must be cool enough to touch with a bare hand. Remove the ller cap slowly in order to relieve pressure. Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.
Illustration 6
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All fuels, most lubricants, and some coolant mixtures are ammable. Flammable uids that are leaking or spilled onto hot surfaces or onto electrical components can cause a re. Fire may cause personal injury and property damage. After the emergency stop button is operated ensure that you allow 15 minutes, before the engine covers are removed. Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result. If the application involves the presence of combustible gases, consult your Perkins dealer and/or your Perkins distributor for additional information about suitable protection devices.
8 Safety Section Fire Prevention and Explosion Prevention
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Remove all ammable combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any ammable 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 ammable materials in protective containers. Do not smoke in areas that are used for storing ammable materials. Do not expose the engine to any ame. Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed correctly. Do not weld on lines or tanks that contain ammable uids. Do not ame cut lines or tanks that contain ammable uid. Clean any such lines or tanks thoroughly with a nonammable solvent prior to welding or ame cutting. Wiring must be kept in good condition. All electrical wires must be correctly routed and securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections. Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers. Arcing or sparking could cause a re. Secure connections, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking.
Oil lters and fuel lters must be correctly installed. The lter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for more information.
Illustration 7
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Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open ames or sparks. Always stop the engine before refueling.
Contact with high pressure fuel may cause uid penetration and burn hazards. High pressure fuel spray may cause a re hazard. Failure to follow these inspection, maintenance and service instructions 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. Ensure that the engine is stopped. Inspect all lines and hoses for wear or for deterioration. The hoses must be correctly routed. The lines and hoses must have adequate support and secure clamps.
Illustration 8
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Gases from a battery can explode. Keep any open ames or sparks away from the top of a battery. Do not smoke in battery charging areas. Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer.
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9 Safety Section Crushing Prevention and Cutting Prevention
Incorrect jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specic instructions. Do not charge a frozen battery. This 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 engine is operated.
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Crushing Prevention and Cutting Prevention

Support the component correctly when work beneath the component is performed. Unless other maintenance instructions are provided, never attempt adjustments while the engine is running. Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstall the guards. Keep objects away from moving fan blades. The fan blades will throw objects or cut objects. When objects are struck, wear protective glasses in order to avoid injury to the eyes. Chips or other debris may y off objects when objects are struck. Before objects are struck, ensure that no one will be injured by ying debris.
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Fire Extinguisher
Make sure that a re extinguisher is available. Be familiar with the operation of the re extinguisher. Inspect the re extinguisher and service the re extinguisher regularly. Obey the recommendations on the instruction plate.
Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are damaged. Leaks can cause res. Consult your Perkins dealer or your Perkins distributor for replacement parts. Replace the parts if any of the following conditions are present:
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 the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds. Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move. Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies.
High pressure fuel line or lines are removed. End ttings 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 ttings are displaced.
Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other parts, and excessive heat.
10 Safety Section Before Starting Engine
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Before Starting Engine

Before the initial start-up of an engine that is new, serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine. Overspeed shutdown should occur automatically for engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop button in order to cut the fuel and/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 the area is free of personnel. If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work correctly, if equipped. 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 circuits are also provided in order to help prevent engine damage. See the Service Manual for repairs and for adjustments.
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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. Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, Engine Starting topic in the Operation Section. Knowing the correct procedure will help to prevent major damage to the engine components. Knowing the procedure will also help to prevent personal injury. To ensure that the jacket water heater (if equipped) is working correctly, check the water temperature gauge (if equipped) and/or the oil temperature gauge (if equipped) during the heater operation. Note: Do not use Lube oil heaters. Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside.
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Engine Stopping
Stop the engine according to the procedure in the Operation and Maintenance Manual, Engine Stopping in order to avoid overheating of the engine and accelerated wear of the engine components. Use the Emergency Stop Button ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected. Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled. In the event of an overspeed condition, the air shutoff valves will operate. After operation, the air shutoff valves must be manually reset.
Engine Starting
Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. If a warning tag is attached to the engine start switch or to the controls DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.
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11 Safety Section Electrical System
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Setpoint adjusters (if equipped) Sensors Wiring Harness
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 power source to the negative terminal of the starting motor. Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical connections before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specic starting instructions. Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge. To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This path may be provided by way of a direct engine ground to the frame. The connections for the grounds should be tight and free of corrosion. The engine alternator must be grounded to the negative - battery terminal with a wire that is adequate to handle the full charging current of the alternator.
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System Description
The system is controlled by an Electronic control Unit (ECU). The ECU contains a microprocessor that has an Electronic Programmable Read Only Memory (EPROM). The operating parameters for the governor are stored in the EPROM. The actuator is connected to the fuel injectors via a mechanical linkage. A laptop computer is used to set the operating parameters of the governor. The laptop computer is connected to the governor via an interface cable. The operating parameters for the governor should only be modied by a trained Perkins representative. Refer to the Special Instruction, Pandoras Digital Governor for more information.
Engine Electronics
Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine damage. The engine is controlled by a digital Pandoras governor. The control system includes the following components.
Control unit Actuator
12 Product Information Section General Information
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Product Information Section General Information

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Welding on Engines with Electronic Controls

NOTICE Proper welding procedures are necessary in order to avoid damage to the engine's ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the component. If removal of the component is not possible, the following procedure must be followed when you weld with a unit that is equipped with an Electronic Engine. The following procedure is considered to be the safest procedure to weld 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, hydraulic components, electrical components, and other components. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage. 1. Stop the engine. Turn the switched power to the OFF position. 2. Disconnect the negative battery cable from the battery. If a battery disconnect switch is provided, open the switch. 3. Disconnect the connectors from the ECM.
Illustration 9
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Use the example above. The current ow from the welder to the ground clamp of the welder will not cause damage to any associated components. (1) (2) (3) (4) (5) (6) (7) (8) Engine Welding rod Keyswitch in the OFF position Battery disconnect switch in the open position Disconnected battery cables Battery Electrical/Electronic component Maximum 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
4. Connect the welding ground cable directly to the part that will be welded. Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings, hydraulic components, electrical components, and ground straps. Note: If electrical/electronic components are used as a ground for the welder, or electrical/electronic components are located between the welder ground and the weld, current ow from the welder could severely damage the component. 5. Protect the wiring harness from welding debris and spatter. 6. Use standard welding practices to weld the materials.
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13 Product Information Section Model Views
Model Views
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Model View Illustrations

4012-46A
The following model views show typical features of the engine. Due to individual applications, engines may appear different from the Illustrations. Note: Only serviced components are identied on the following Illustrations.
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Illustration 10 Typical example Left side view of engine (1) Radiator cap (2) Thermostat housing (3) Coolant temperature switch (4) Air cleaner (5) Restriction indicator for air cleaner (6) Air shutoff valve (7) Timing inspection hole (8) Inspection covers for crankcase (9) 3x Oil lters (10) Oil cooler (11) Oil drain plug (12) Oil level gauge (13) Oil ller (14) Crankshaft damper (15) Engine crankcase breather
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Illustration 11 Typical example Right side view of engine (1) Air shutoff valve (2) Restriction indicator for air cleaner (3) Air cleaner (4) Electronic governor control unit (5) Coolant temperature switch (6) Thermostat housing (7) Aftercooler (8) Radiator (9) Engine crankcase breather (10) Alternator (11) Primary fuel lter/water separator (12) Oil pump (13) (14) (15) (16) (17) (18) Fuel priming pump Oil pan drain plug Oil cooler 3x Oil lters Starter relay 2x Starting motors
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Engine Description
The 4012-46A Engine model is designed for power generation. The engine is available with turbocharged aftercooled aspiration.
Engine Specications
Note: The number 1 cylinders are to the front. The front of the engine is farthest from the ywheel. Bank A cylinders are on the right-hand side of the engine. Bank B cylinders are on the left-hand side of the engine. To determine the left and right sides of the engine, stand behind the ywheel and face the dampers.
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The engine lubricating oil is supplied by a gear-driven pump. The lubrication oil is cooled and ltered. Bypass valves provide unrestricted ow of lubrication oil to the engine parts when oil viscosity is high. Bypass valves can also provide unrestricted ow of lubrication oil to the engine parts if the oil lter element should become plugged. Engine efciency, efciency of emission controls, and engine performance depend on adherence to proper operation and maintenance recommendations. Engine performance and efciency 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.
Illustration 12 4012-46A Engine model (A) (B) (X) (Y) Bank Bank Inlet valves Exhaust valves
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Table 1
4012-46A Engine Specications Cycle Number of Cylinders Conguration Bore Stroke Displacement Compression Ratio Rotation (ywheel end) Firing Order Inlet Valve Lash (Cold) Exhaust Valve Lash (Cold) 4 Stroke 12 Vee-form 160 mm (6.299 inch) 190 mm (7.480 inch) 45.84 L (2797.328 in3) 13:1 Counterclockwise 1A-6B-5A-2B-3A-4B-6A-1B-2A5B-4A-3B 0.40 mm (0.016 inch) 0.40 mm (0.016 inch)
Engine Cooling and Lubrication

The cooling system consists of the following components:
Gear-driven water pumps Water temperature regulators which regulate the

engine coolant temperature
Gear-driven oil pump (gear type) Oil coolers
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17 Product Information Section Product Identication Information
Product Identication Information

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Table 3
Type of engine (Diesel) F L A B D M TG TAG TAG1 TAG2 TAG3 TWG TWG2 TWG3 TRG1 TEG2 TEG3 TRW2 TRW3
Plate Locations and Film Locations

Engine Identication
Perkins engines are identied by an engine serial number. A typical example of an engine serial number is DGB M**** U00001V. D _________ ________________________________ Made in Stafford
___________________________ Application (Table 2) G _________ _______________________Type of engine (Table 3) B _________ _______________ Number of cylinders (Table 4) M _________ _________________________Fixed build number ***** _________ ___________________Built in the United Kingdom U _________ ___________________________Engine Number 00001 _________ ____________________________Year of Manufacture V _________ Table 2 Table 4
K N P R S W X
Number of Cylinders F H M R 6 8 12 16
Perkins dealers and Perkins distributors require all of these numbers in order to determine the components that were included in the engine. This permits accurate identication of replacement part numbers.
Application G Genset
18 Product Information Section Product Identication Information
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Serial Number Plate
Illustration 13 Serial number plate
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Illustration 14
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The location of the serial number plate for vee-form engines
The engine serial number plate contains the following information:
The serial number plate (1) on a vee-form engine is located on the rear face of the cylinder block (bank A). See Illustration 14.
Place of manufacture Telephone number of manufacturer Fax number of manufacturer Type of engine Engine serial number Rated speed Power output Engine timing Rating
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19 Operation Section Lifting and Storage
Operation Section Lifting and Storage

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To remove the engine ONLY, use the lifting eyes that are on the engine. If necessary, remove engine components in order to avoid damage from the lifting device. Lifting eyes are designed and installed for specic engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting xtures obsolete. If alterations are made, ensure that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information regarding xtures for correct engine lifting.
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Engine Lifting
NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight.
Engine Storage
Refer to Perkins Engine Company Limited, Stafford, ST16 3UB for information on engine storage. There are three different levels of engine storage. Level A, B and C.
Level A
Level A will give protection for 12 months for diesel engines and for gas engines. This level is used for engines that are transported in a container or by a truck.
Level B
This level is additional to level A. Level B will give protection under normal conditions of storage from 15 to +55C (5 to 99F) and 90% relative humidity, for a maximum of 2 year.
Level C
This level is additional to level B. Level C will give protection for ve years in tropical or in arctic climates. Level C also meets MOD NES 724 Level J for Europe, when engines are stored in an unheated building or in the open under a waterproof cover.
Illustration 15
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Use a hoist to remove heavy components. Use a lifting beam (A) 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.
20 Operation Section Features and Controls
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Features and Controls

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Monitoring System
The engine is equipped with sensors or switches to monitor the following parameters:
Coolant temperature (Switch) Oil pressure (Switch) Intake manifold boost pressure (Sensor) Exhaust temperature (if equipped) Engine speed (Sensor) Engine overspeed (Sensor or Switch)
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Illustration 16 Right side view of engine (1) (2) (3) (4) (5) Electronic control unit (ECU) Coolant temperature switch Boost pressure sensor Speed sensor Oil pressure switch
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Sensors and Electrical Components

Sensor Locations
Illustrations 16 and 17 show the typical locations of the sensors on the engine. Specic engines may appear different from the illustrations due to differences in applications. Illustration 16 shows the location of the Electronic Control Unit (ECU).
Illustration 17 Left side view of engine (2) (3) (5) (6) Coolant temperature switch Boost pressure sensor Oil pressure switch Overspeed sensor
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Coolant Temperature Switches
Speed Sensor
Illustration 18 Coolant temperature switch
g01231514
Illustration 20 Speed sensor
g01231517
The coolant temperature switches (2) monitor the engine coolant temperature. The switches are supplied for connecting to an OEM supplied panel.
The speed sensor (4) should be serviced at the required maintenance interval. Refer to the Operation and Maintenance Manual, Speed Sensor, Clean/Inspect.
Boost Pressure Sensors
Failure of the Speed Sensor

If the ECU (1) does not receive a signal from the speed sensor (4), the engine cannot run. If the ECU does not receive a signal from the speed sensor (4), the engine will shut down. A faulty speed sensor should be replaced. Note: Intermittent failure of the speed sensor will cause the engine to run erratically. This may also cause overspeed.
Illustration 19 Boost pressure sensor
g01231515
The boost pressure sensor (3) measures the pressure in the inlet air manifold. A signal is sent to the ECU (1).
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Engine Oil Pressure Switch
Illustration 21 Engine oil pressure switch
g01278615
The engine oil pressure switch (5) is mounted in the main oil gallery. The engine oil pressure switches are supplied for connecting to an OEM supplied panel (1).
Overspeed Sensor
Illustration 22 Overspeed sensor
g01231518
The signal from the overspeed sensor (6) is connected to the overspeed switch or the overspeed circuit in the OEM supplied panel.
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23 Operation Section Engine Starting
Engine Starting
i02415220
Before Starting Engine

Before the engine is started, perform the required daily maintenance and any other periodic maintenance that is due. Refer to the Operation and Maintenance Manual, Maintenance Interval Schedule for more information. Note: Do not start the engine or move any of the controls if there is a DO NOT OPERATE warning tag or similar warning tag attached to the start switch or to the controls. 1. Open the fuel supply valve (if equipped). 2. If the engine has not been started for several weeks, fuel may have drained from the fuel system. Also, when fuel lters have been changed, some air pockets will be trapped in the engine. In these instances, prime the fuel system. Refer to the Operation and Maintenance Manual, Fuel System - Prime for more information.
b. Turn the keyswitch to the START position. Hold the keyswitch in this position until the oil pressure gauge indicates 100 kPa (14.5040 psi). Continue to hold the keyswitch in the START position for an additional 10 seconds. Note: The keyswitch is part of the OEM supplied panel. The exact procedure for starting may vary. Refer to OEM supplied instructions for the correct starting procedure. c. Turn the keyswitch to the STOP position. d. Reconnect the speed pickup connector. The engine is now ready to run.
i02415221
Starting the Engine

Normal Engine Starting Procedure
Note: When possible, ensure that the engine is not started under load. 1. Turn the keyswitch to the START position. The engine should start immediately. 2. Allow the keyswitch to return to the RUN position after the engine starts. If the engine does not start after 10 seconds, return the keyswitch in the RUN position for 10 seconds. Then repeat Steps 1 and 2. Note: If the engine fails to start after three attempts, investigate the cause.
Illustration 23
g01230837
3. After the engine has started follow Steps 3.a through 3.d. a. Check the oil pressure. b. Inspect the engine for leaks. c. Ensure that the batteries for the engine are receiving a charge. d. After the engine has run for ve minutes, check the engine monitoring systems. Ensure that the engine is operating correctly before the load is applied.
3. Ensure that the two air shutoff valves (1) are in the OPEN position. 4. If the engine has not been started for more than three months, the engine oil system must be primed. Follow Steps 4.a through 4.d in order to prime the engine oil system. a. Ensure that the governor stays in the STOP position by disconnecting the speed pickup connector on the governor control.
24 Operation Section Engine Starting
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Cold Weather Starting
Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. Startability will be improved at temperatures below +10 C (+50 F) from the use of a jacket water heater or extra battery capacity.
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25 Operation Section Engine Operation
Engine Operation
i02415225
i02415226
Fuel Conservation Practices

The efciency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efciency in all applications. Follow the recommended procedures in order to attain optimum performance for the life of the engine.
Engine Operation
Correct operation and maintenance are key factors in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenance Manual are followed, costs can be minimized and engine service life can be maximized. Gauge readings (if equipped) should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments. Signicant changes in the readings should be investigated.
Avoid spilling fuel. Fuel expands when the fuel is

warmed up. The fuel may overow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed. Use only the recommended fuels.
Be aware of the properties of the different fuels. Avoid unnecessary running at a low load. If the
engine is not under load, the engine should be shut down.
Observe the air cleaner service indicator frequently.

The air cleaner elements should be replaced when the air cleaner elements are dirty. battery cell will overwork the alternator. This will consume excess power and excess fuel. The drive belts should be in good condition. tight. The connections should not leak. working order.
Maintain the electrical systems. One damaged
Ensure that the drive belts are correctly adjusted. Ensure that all of the connections of the hoses are Ensure that the driven equipment is in good Cold engines consume excess fuel. Utilize heat
from the jacket water system and the exhaust system, when possible. Keep cooling system components clean and keep cooling system components in good repair. Never operate the engine without water temperature regulators. All of these items will help maintain operating temperatures.
26 Operation Section Engine Stopping
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Engine Stopping
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i02415231
After Stopping Engine

Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan.
Stopping the Engine

Note: Individual applications will have different control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to stop the engine. 1. Remove the load from the engine. Allow the engine to run off load for ve minutes in order to cool the engine. 2. Stop the engine after the cool down period according to the shutoff system on the engine and turn the ignition key switch to the OFF position. If necessary, refer to the instructions that are provided by the OEM.
i02415230
If the engine is equipped with a service hour meter,

note the reading. Perform the maintenance that is in the Operation and Maintenance Manual, Maintenance Interval Schedule.
Check the crankcase oil level. Maintain the oil level

between the MIN mark and the MAX mark on the engine oil level gauge.
If necessary, perform minor adjustments. Repair
any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. accumulation of moisture in the fuel. Do not overll the fuel tank.
Fill the fuel tank in order to help prevent
Emergency Stopping
NOTICE Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure. The engine should be equipped with an emergency stop button. For more information about the emergency stop button, refer to the OEM information. Ensure that any components for the external system that support the engine operation are secured after the engine is stopped. In the event of an overspeed condition, the air shutoff valves will operate. After operation, the air shutoff valves must be manually reset.
NOTICE Only use antifreeze/coolant mixtures recommended in the Coolant Specications that are in the Operation and Maintenance Manual. Failure to do so can cause engine damage.
Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
Allow the engine to cool. Check the coolant level. Check the coolant for correct antifreeze protection
and the 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.
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27 Maintenance Section Rell Capacities
Maintenance Section Rell Capacities

i03754130
Table 7
Engine Rell Capacities Compartment or System Minimum Capacity of Fuel Tank 4012-46A 14000 L (3000 Imp gal)
Rell Capacities Fluid Recommendations

Lubrication System
The rell capacities for the engine crankcase reect the approximate capacity of the crankcase or sump plus standard oil lters. Auxiliary oil lter systems will require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil lter. Refer to the Operation and Maintenance Manual, Maintenance Section for more information on Lubricant Specications.
Table 5
i04328169
General Lubricant Information

The following lubricant recommendations must be followed.
Engine Manufacturers Association (EMA) Oils

The Engine Manufacturers Association Recommended Guideline on Diesel Engine Oil is recognized by Perkins. For detailed information about this guideline, see the latest edition of EMA publication, EMA DHD -1.
Engine Rell Capacities Compartment or System Crankcase Oil Sump(1)

(1)
4012-46A 178 L (39.2 Imp gal)
These values are the total capacities for the crankcase oil sump which includes the standard factory installed oil lters and oil coolers. Engines with auxiliary oil lters will require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil lter.
API Oils
The Engine Oil Licensing and Certication System by the American Petroleum Institute (API) is recognized by Perkins. For detailed information about this system, see the latest edition of the API publication No. 1509. Engine oils that bear the API symbol are authorized by API.
Cooling System
Refer to the OEM specications for the External System capacity. This capacity information will be needed in order to determine the amount of coolant and antifreeze that is required for the Total Cooling System.
Table 6
Engine Rell Capacities Compartment or System External System Per

(1)
Liters
OEM(1)
The External System includes a radiator with the following components: heat exchanger and piping. Refer to the OEM specications. Enter the value for the capacity of the External System in this column.
Illustration 24 Typical API symbol
g00546535
Fuel System
Refer to the OEM specications for additional information on the capacity of the Fuel System.
Diesel engine oils CC, CD, CD-2, and CE have not been API authorized classications since 1 January 1996. Table 8 summarizes the status of the classications.
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Table 8
API Classications Current CH-4, , CI-4 (1)
Obsolete CE, CC, CD CD-2

(1)
The oil CD-2 is for a two-cycle diesel engine. Perkins does not sell engines that utilize CD-2 oil.
Terminology
Certain abbreviations follow the nomenclature of SAE J754. Some classications follow SAE J183 abbreviations, and some classications follow the EMA Recommended Guideline on Diesel Engine Oil. In addition to Perkins denitions, there are other denitions that will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in this publication, Fluid Recommendations/Engine Oil topic (Maintenance Section).
DHD-1 oils will meet the needs of high performance Perkins diesel engines that are operating in many applications. The tests and the test limits that are used to dene DHD-1 are similar to the new API CH-4 classication. Therefore, these oils will also meet the requirements for diesel engines that require low emissions. DHD-1 oils are designed to control the harmful effects of soot with improved wear resistance and improved resistance to plugging of the oil lter. These oils will also provide superior piston deposit control for engines with either two-piece steel pistons or aluminum pistons. All DHD-1 oils must complete a full test program with the base stock and with the viscosity grade of the nished commercial oil. The use of API Base Oil Interchange Guidelines are not appropriate for DHD-1 oils. This feature reduces the variation in performance that can occur when base stocks are changed in commercial oil formulations. DHD-1 oils are recommended for use in extended oil change interval programs that optimize 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 dealer or your Perkins distributor has the specic 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 requirements of the low emissions diesel engines. API CH-4 oils are also acceptable for use in older diesel engines and in diesel engines that use high sulfur diesel fuel. API CH-4 oils may be used in Perkins engines that use API CG-4 and API CF-4 oils. API CH-4 oils will generally exceed the performance of API CG-4 oils in the following criteria: deposits on pistons, control of oil consumption, wear of piston rings, valve train wear, viscosity control, and corrosion. Three new engine tests were developed for the API CH-4 oil. The rst test specically evaluates deposits on pistons for engines with the two-piece steel piston. This test (piston deposit) also measures the control of oil consumption. A second test is conducted with moderate oil soot. The second test measures the following criteria: wear of piston rings, wear of cylinder liners, and resistance to corrosion. A third new test measures the following characteristics with high levels of soot in the oil: wear of the valve train, resistance of the oil in plugging the oil lter, and control of sludge.
Engine Oil
Commercial Oils
The performance of commercial diesel engine oils is based on American Petroleum Institute (API) classications. These API classications are developed in order to provide commercial lubricants for a broad range of diesel engines that operate at various conditions. Only use commercial oils that meet the following classications:
API CG-4 API CH-4 API CI-4

In order to make the correct choice of a commercial oil, refer to the following explanations: EMA DHD-1 The Engine Manufacturers Association (EMA) has developed lubricant recommendations as an alternative to the API oil classication system. DHD-1 is a Recommended Guideline that denes a level of oil performance for these types of diesel engines: high speed, four stroke cycle, heavy-duty, and light duty. DHD-1 oils may be used in Perkins engines when the following oils are recommended: API CH-4, API CG-4, and API CF-4. DHD-1 oils are intended to provide superior performance in comparison to API CG-4 and API CF-4.
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In addition to the new tests, API CH-4 oils have tougher limits for viscosity control in applications that generate high soot. The oils also have improved oxidation resistance. API CH-4 oils must pass an additional test (piston deposit) for engines that use aluminum pistons (single piece). Oil performance is also established for engines that operate in areas with high sulfur diesel fuel. All of these improvements allow the API CH-4 oil to achieve optimum oil change intervals. API CH-4 oils are recommended for use in extended oil change intervals. API CH-4 oils are recommended for conditions that demand a premium oil. Your Perkins dealer or your Perkins distributor has specic guidelines for optimizing oil change intervals. Some commercial oils that meet the API classications may require reduced oil change intervals. To determine the oil change interval, closely monitor the condition of the oil and perform a wear metal analysis. NOTICE Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.
Use the following guidelines for fuel sulfur levels that exceed 1.5 percent:
Choose an oil with the highest TBN that meets one

of these classications: EMA DHD-1 and API CH-4.
Reduce the oil change interval. Base the oil
change interval on the oil analysis. Ensure that the oil analysis includes the condition of the oil and a wear metal analysis.
Excessive piston deposits can be produced by an oil with a high TBN. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore. NOTICE Operating Direct Injection (DI) diesel engines with fuel sulphur levels over 0.5 percent will require shortened oil change intervals in order to help maintain adequate wear protection.
Table 9
Percentage of Sulfur in the fuel Lower than 0.5 0.5 to 1.0 Greater than 1.0
Oil change interval Normal 0.75 of normal 0.50 of normal
Total Base Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines
The Total Base Number (TBN) for an oil depends on the fuel sulfur level. For direct injection engines that use distillate fuel, the minimum TBN of the new oil must be ten times the fuel sulfur level. The TBN is dened by ASTM D2896. The minimum TBN of the oil is 5 regardless of fuel sulfur level. Illustration 25 demonstrates the TBN.
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 10 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine. Refer to Table 10 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated. Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.
Illustration 25
g00799818
(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.
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Table 10
Lubricants for Cold Weather

Engine Oil Viscosity Ambient Starting Temperature Temperatures below 15 C (5 F) 15 C (5 F) to 0 C (32. F) 0 C (32. F) to 32 C (89.5 F) Temperatures above 32 C (89.5 F)
EMA LRG-1 API CH-4 Viscosity Grade SAE 10W30 SAE 15W40 SAE 15W40 SAE 15W40
When an engine is started and an engine is operated in ambient temperatures below 20 C (4 F), use multigrade oils that are capable of owing in low temperatures. These oils have lubricant viscosity grades of SAE 10W or SAE 15W. When an engine is started and operated in ambient temperatures below 30 C (22 F), use a synthetic base stock multigrade oil with an 0W viscosity grade or with a 5W viscosity grade. Use an oil with a pour point that is lower than 50 C (58 F). The number of acceptable lubricants is limited in cold-weather conditions. Perkins recommends the following lubricants for use in cold-weather conditions: First Choice Use oil with an EMA DHD-1 Recommended Guideline. Use a CH-4 oil that has an API license. The oil should be either SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 lubricant viscosity grade. Second Choice Use an oil that has a CH-4 additive package. Although the oil has not been tested for the requirements of the API license, the oil must be either SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40. NOTICE Shortened engine service life could result if second choice oils are used.
Synthetic Base Stock Oils

Synthetic base oils are acceptable for use in these engines if these oils meet the performance requirements that are specied for the engine. Synthetic base oils generally perform better than conventional oils in the following two areas:
Synthetic base oils have improved ow at low

temperatures especially in arctic conditions.
Synthetic base oils have improved oxidation
stability especially at high operating temperatures.
Some synthetic base oils have performance characteristics that enhance the service life of the oil. Perkins does not recommend the automatic extending of the oil change intervals for any type of oil.
Re-rened Base Stock Oils

Re-rened base stock oils are acceptable for use in Perkins engines if these oils meet the performance requirements that are specied by Perkins. Re-rened base stock oils can be used exclusively in nished oil or in a combination with new base stock oils. The US military specications and the specications of other heavy equipment manufacturers also allow the use of re-rened base stock oils that meet the same criteria. The process that is used to make re-rened base stock oil should adequately remove all wear metals that are in the used oil and all the additives that are in the used oil. The process that is used to make re-rened base stock oil generally involves the process of vacuum distillation and hydrotreating the used oil. Filtering is adequate for the production of high quality, re-rened base stock oil.
Aftermarket Oil Additives

Perkins does not recommend the use of aftermarket additives in oil. It is not necessary to use aftermarket additives in order to achieve the maximum service life of the engine or rated performance. Fully formulated, nished 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 nished oils with performance characteristics that meet industry standards. There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in nished oil. Aftermarket additives may not be compatible with the additive package of the nished oil, which could lower the performance of the nished oil. The aftermarket additive could fail to mix with the nished oil. This could produce sludge in the crankcase. Perkins discourages the use of aftermarket additives in nished oils.
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To achieve the best performance from a Perkins engine, conform to the following guidelines:
Cetane number_______________________________________50 Viscosity___________ 1.5 to 5.0 cSt at 40 C (104 F) Carbon residue__________________________________0.20%

Ramsbottom on 10% reidue
Select the correct oil, or a commercial oil that meets
the EMA Recommended Guideline on Diesel Engine Oil or the recommended API classication. order to nd the correct oil viscosity grade for your engine. new oil and install a new oil lter.
See the appropriate Lubricant Viscosities table in
Sulfur content___________ 0.05% of mass, maximum Distillation___________________56% at 350 C (662 F) Lubricity______________________________460 micrometers
maximum wear scar on ISO 12156 - 1 Class A2 Fuels
At the specied interval, service the engine. Use Perform maintenance at the intervals that are
specied in the Operation and Maintenance Manual, Maintenance Interval Schedule.
Cetane number_______________________________________45 Viscosity___________ 1.5 to 5.5 cSt at 40 C (104 F) Carbon residue__________________________________0.20%

Ramsbottom on 10% reidue
Oil analysis
Oil samples should be taken on a regular basis for oil analysis. Oil analysis will complement the preventive maintenance program. The oil analysis is a diagnostic tool that is used to determine oil performance and component wear rates. Contamination can be identied and measured by using the oil analysis. The oil analysis includes the following tests:
Sulfur content___________ 0.05% of mass, maximum Distillation___________________56% at 350 C (662 F) Lubricity______________________________460 micrometers
maximum 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 root cause of problems during cold start. This will affect combustion. Viscosity This is the resistance to ow of a uid. If this resistance is outside the limits, the engine and the engine starting performance in particular can be affected. Sulfur High sulfur content of the fuel is not normally found in Europe, North America or Australasia. This can cause engine wear. When only high sulfur fuels are available, it will be necessary that high alkaline lubricating oil is used in the engine or that the lubricating oil change interval is reduced. Distillation This is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light weight hydrocarbons can affect the characteristics of combustion. Lubricity
The Wear Rate Analysis monitors the wear of the
metals in the engine. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increase in the rate of engine wear metal in the oil is as important as the quantity of engine wear metal in the oil. contamination of the oil by water, glycol, or fuel. of the lubricating properties of the oil. An infrared analysis is used to compare the properties of new oil to the properties of the used oil sample. This analysis allows technicians to determine the amount of deterioration of the oil during use. This analysis also allows technicians to verify the performance of the oil according to the specication during the entire oil change interval.
Tests are conducted in order to detect
The Oil Condition Analysis determines the loss
Fuel Specications
Fuel Recommendations
To get the correct power and performance from the engine, use a fuel of the correct quality. The recommended fuel specication for Perkins engines is shown below: Class A1 Fuels
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This is the capability of the fuel to prevent pump wear. Diesel engines have the ability to burn various fuels. These fuels are divided into two general groups:
Deterioration of emissions and misre at certain

operating conditions NOTICE Water emulsion fuels: These fuels are not permitted Refer to the following fuel specications for North America. The preferred fuels provide maximum engine service life and performance. The preferred fuels are distillate fuels. These fuels are commonly called diesel fuel or gas oil. The permissible fuels are crude oils or blended fuels. Use of these fuels can result in higher maintenance costs and in reduced engine service life. Diesel fuels that meet the specications in Table 11 will help to provide maximum engine service life and performance. In North America, diesel fuel that is identied as No. 2-D in ASTM D975 generally meets the specications. Table 11 is for diesel fuels that are distilled from crude oil. Diesel fuels from other sources could exhibit detrimental properties that are not dened or controlled by this specication.
Table 11
Group 1 (preferred fuels) Group 2 (permissible fuels)

Group 1 (preferred fuels): Specication DERV to EN590 Note: Only use Arctic fuels when the temperature is below 0 C (32 F). Do not use Arctic fuels when the ambient temperature is above 0 C (32 F). To ensure that the time period between cranking the engine and rst re is kept to a minimum, only use fuel of the correct viscosity and at the correct temperature. Gas oil to BS29 Class A2 Note: If low sulfur or low sulfur aromatic fuels are used, then fuel additives can be used to increase lubricity. Group 2 (permissible fuels): Specication These fuel specications are considered acceptable for issues of warranty. However, these fuels may reduce the life of the engine, the maximum power of the engine and the fuel efciency of the engine. ASTM D975 - 91 Class 1D JP7, Mil T38219 NATO F63 NOTICE These fuels should have a wear scar value of 650 micrometers maximum *HFRR to ISO 12156 - 1.* Low temperature fuels Special fuels for use in cold weather may be available for engine operation at temperatures below 0 C (32 F). These fuels limit the formation of wax in the fuel oil at low temperatures. If wax forms in the fuel oil, this could stop the ow of fuel oil through the lter. Note: These fuels that lack lubricity may cause the following problems:
Perkins Specications for Distillate Diesel Fuel Specications Aromatics Ash Carbon Residue on 10% Bottoms Cetane Number Requirements 35% maximum 0.02% maximum (weight) 0.35% maximum (weight) 40 minimum (DI engines) The cloud point must not exceed the lowest expected ambient temperature. ASTM Test D1319 D482 D524 D613
Cloud Point
(continued)
Low engine power Difcult starting in hot conditions or in cold

conditions
White smoke
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(Table 11, contd)
Copper Strip Corrosion
No. 3 maximum 10% at 282 C (540 F) maximum 90% at 360 C (680 F) maximum legal limit 30 minimum 45 maximum 6 C (10 F) minimum below ambient temperature 0.2% maximum
D130
Distillation
D86
NOTICE Operating with fuels that do not meet the Perkins recommendations can cause the following effects: Starting difculty, poor combustion, deposits in the fuel injectors, reduced service life of the fuel system, deposits in the combustion chamber, and reduced service life of the engine. NOTICE Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel must NOT be used in Perkins diesel engines. Severe component wear and component failures will result if HFO type fuels are used in engines that are congured to use distillate fuel. In extreme cold ambient conditions, you may use the distillate fuels that are specied in Table 12. However, the fuel that is selected must meet the requirements that are specied in Table 11. These fuels are intended to be used in operating temperatures that are down to 54 C (65 F).
Table 12
Flash Point API Gravity
D93 D287
Pour Point
D97 D3605 or D1552 D445
Sulfur
(1)
Kinematic Viscosity (2) Water and Sediment Water Sediment Gum and Resins
(3)
2.0 cSt minimum and 4.5 cSt maximum at 40 C (104 F) 0.1% maximum 0.1% maximum 0.05% maximum (weight) 10 mg per 100 mL maximum 0.38 mm (0.015 inch) maximum at 25 C (77 F)
Distillate Fuels D1796 D1744 D473 D381

(1)
(1)
Specication MIL-T-5624R ASTM D1655 MIL-T-83133D
Grade JP-5 Jet-A-1 JP-8
Lubricity (4)
(1)
D6079
The fuels that are listed in this Table may not meet the requirements that are specied in the Perkins Specications for Distillate Diesel Fuel Table. Consult the supplier for the recommended additives in order to maintain the correct fuel lubricity.
Perkins fuel systems and engine components can operate on high sulfur fuels. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal components. Fuel sulfur levels above 0.5 percent may signicantly shorten the oil change interval. For additional information, see this publication, Fluid Recommendations/Engine Oil topic (Maintenance Section). (2) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain a 1.4 cSt viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to bring down the viscosity to a 20 cSt viscosity. (3) Follow the test conditions and procedures for gasoline (motor). (4) The lubricity of a fuel is a concern with low sulfur fuel. To determine the lubricity of the fuel, use either the ASTM D6078 Scufng Load Wear Test (SBOCLE) or the ASTM D6079 High Frequency Reciprocating Rig (HFRR) test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system.
These fuels are lighter than the No. 2 grades of fuel. The cetane number of the fuels in Table 12 must be at least 40. If the viscosity is below 1.4 cSt at 38 C (100 F), use the fuel only in temperatures below 0 C (32 F). Do not use any fuels with a viscosity of less than 1.2 cSt at 38 C (100 F). Fuel cooling may be required in order to maintain the minimum viscosity of 1.4 cSt at the fuel injection pump. There are many other diesel fuel specications that are published by governments and by technological societies. Usually, those specications do not review all the requirements that are addressed in this specication. To ensure optimum engine performance, a complete fuel analysis should be obtained before engine operation. The fuel analysis should include all of the properties that are listed in Table 11.
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Recommendations for Biodiesel

Biodiesel can be blended with distillate diesel fuel. The blends can be used as fuel. The most commonly available biodiesel blends are B5, which is 5 percent biodiesel and 95 percent distillate diesel fuel. B20, which is 20 percent biodiesel and 80 percent distillate diesel fuel. Note: The percentages given are volume-based. The U.S. distillate diesel fuel specication ASTM D975-09a includes up to B5 (5 percent) biodiesel. European distillate diesel fuel specication EN590: 2010 includes up B7 (7 percent) biodiesel. Specication Requirements The neat biodiesel must conform to the latest EN14214 or ASTM D6751 (in the USA). The biodiesel can only be blended in mixture of up to 20% by volume in acceptable mineral diesel fuel meeting latest edition of EN590 or ASTM D975 S15 designation. In United States Biodiesel blends of B6 to B20 must meet the requirements listed in the latest edition of ASTM D7467 (B6 to B20) and must be of an API gravity of 30-45. In North America biodiesel and biodiesel blends must be purchased from the BQ-9000 accredited producers and BQ-9000 certied distributors. In other areas of the world, the use of biodiesel that is BQ-9000 accredited and certied, or that is accredited and certied by a comparable biodiesel quality body to meet similar biodiesel quality standards is required. Engine Service Requirements Aggressive properties of biodiesel fuel may cause debris in the fuel tank and fuel lines to be released and entrained in the fuel. This effectively cleans the fuel system. This cleaning of the fuel system can prematurely block of the fuel lters. Perkins recommend that after the initial usage of B20 biodiesel blended fuel the fuel lters must be replaced at 50 hours. Glycerides present in biodiesel fuel will also cause fuel lters to become blocked more quickly. Therefore the regular service interval should be reduced to 250 hours.
Crankcase oil fuel dilution can be higher when
biodiesel or biodiesel blends are used. This increased level of fuel dilution when using biodiesel or biodiesel blends is related to the typically lower volatility of biodiesel. In-cylinder emissions control strategies utilized in many of the industrial latest engine designs may lead to a higher level of biodiesel concentration in the sump. There is recent evidence that the unburnt fuel can form treacle like deposits in the engine oil pan. If left to accumulate the deposits have been shown to block oil ways leading to engine failure. This reinforces the need to operate a reduced oil change interval. to check the quality of the engine oil if biodiesel fuel is used. Ensure that the level of biodiesel in the fuel is noted when the oil sample is taken.
Perkins recommend the use of oil analysis in order
Performance Related Issues Due to the lower energy content than the standard distillate fuel B20 will cause a power loss. In addition, over time the power may deteriorate further due to deposits in the fuel injectors. Biodiesel and biodiesel blends are known to cause an increase in fuel system deposits, most signicant of which are deposits within the fuel injector. These deposits can cause a loss in power due to restricted or modied fuel injection or cause other functional issues associated with these deposits.
The engine may be difcult to start in cold

conditions.
The turbochargers may have a reduced service life. The engine emissions can deteriorate.
General Requirements Biodiesel has poor oxidation stability, which can result in long-term problems in the storage of biodiesel. Biodiesel fuel should be used within 6 months of manufacture. Equipment should not be stored with the B20 biodiesel blends in the fuel system for longer than 3 months. Due to poor oxidation stability and other potential issues, it is strongly recommended that engines with limited operational time either not use B20 biodiesel blends or, while accepting some risk, limit biodiesel blend 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.
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Perkins strongly recommended that seasonally operated engines have the fuel systems, including fuel tanks, ashed with conventional diesel fuel before prolonged shutdown periods. An example of an application that should seasonally ush the fuel system is a combine harvester. Microbial contamination and growth can cause corrosion in the fuel system and premature plugging of the fuel lter. Consult your supplier of fuel for assistance in selecting appropriate anti-microbial additive. Water accelerates microbial contamination and growth. When biodiesel is compared to distillate fuels, water is naturally more likely to exist in the biodiesel. It is therefore essential to check frequently and if necessary, drain the water separator. Materials such as brass, bronze, copper, lead, tin, and zinc accelerate the oxidation process of the biodiesel fuel. The oxidation process can cause deposits formation therefore these materials must not be used for fuel tanks and fuel lines.
NOTICE Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the proper operating temperature. Cooling system problems can develop without water temperature regulators. 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 coolant is as important as the quality of the fuel and the lubricating oil. Coolant is normally composed of three elements: Water, additives, and glycol.
Cooling System Specications

General Coolant Information
NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool rst. NOTICE If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system must be either protected to the lowest outside temperature or drained completely to prevent damage. NOTICE Frequently check the specic gravity of the coolant for proper freeze protection or for anti-boil protection. Clean the cooling system for the following reasons:
Water
Water is used in the cooling system in order to transfer heat. Distilled water or deionized water is recommended for use in engine cooling systems. DO NOT use the following types of water in cooling systems: Hard water, softened water that has been conditioned with salt, and sea water. If distilled water or deionized water is not available, use water with the properties that are listed in Table 13.
Table 13
Acceptable Water Property Chloride (Cl) Sulfate (SO4) Total Hardness Total Solids Acidity Maximum Limit 40 mg/L 100 mg/L 170 mg/L 340 mg/L pH of 5.5 to 9.0
Contamination of the cooling system Overheating of the engine Foaming of the coolant
For a water analysis, consult one of the following sources:
Local water utility company Agricultural agent Independent laboratory
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Additives
Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives or insufcient amounts of additives enable the following conditions to occur:
Table 14
Ethylene Glycol Concentration 50 Percent 60 Percent Freeze Protection 36 C (33 F) 51 C (60 F) Boil Protection 106 C (223 F) 111 C (232 F)
Corrosion Formation of mineral deposits Rust Scale Foaming of the coolant

Many additives are depleted during engine operation. These additives must be replaced periodically. Additives must be added at the correct concentration. Overconcentration of additives can cause the inhibitors to drop out-of-solution. The deposits can enable the following problems to occur:
NOTICE Do not use propylene glycol in concentrations that exceed 50 percent glycol because of the reduced heat transfer capability of propylene glycol. Use ethylene glycol in conditions that require additional protection against boiling or freezing.
Table 15
Propylene Glycol Concentration 50 Percent Freeze Protection 29 C (20 F) Anti-Boil Protection 106 C (223 F)
Formation of gel compounds Reduction of heat transfer Leakage of the water pump seal Plugging of radiators, coolers, and small passages Glycol
Glycol in the coolant helps to provide protection against the following conditions:
To check the concentration of glycol in the coolant, measure the specic gravity of the coolant.
Coolant Recommendations
The following two coolants are used in Perkins diesel engines: Preferred Perkins Extended Life Coolant (ELC) Acceptable A commercial heavy-duty coolant that meets ASTM D6210 specications NOTICE Do not use a commercial coolant/antifreeze that only meets the ASTM D3306 specication. This type of coolant/antifreeze is made for light automotive applications. Perkins recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide optimum heavy-duty performance as a coolant. This ratio may be increased to 1:2 water to glycol if extra freezing protection is required. A mixture of Supplement Coolant Additive (SCA) and water is acceptable. Perkins recommends a six percent to eight percent concentration of SCA in those cooling systems. Distilled water or deionized water is preferred. Water which has the recommended properties may be used.
Boiling Freezing Cavitation of the water pump

For optimum performance, Perkins recommends a 1:1 mixture of a water/glycol solution. Note: Use a mixture that will provide protection against the lowest ambient temperature. Note: 100 percent pure glycol will freeze at a temperature of 13 C (8.6 F). Most conventional coolants use ethylene glycol. Propylene glycol may also be used. In a 1:1 mixture with water, ethylene and propylene glycol provide similar protection against freezing and boiling. See Tables 14 and 15.
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Engines that are operating in an ambient temperature above 43 C (109.4 F) must use SCA and water. Engines that operate in an ambient temperature above 43 C (109.4 F) and below 0 C (32 F) due to seasonal variations consult your Perkins dealer or your Perkins distributor for the correct level of protection.
Table 16
ELC Cooling System Maintenance

Correct additions to the Extended Life Coolant
NOTICE Use only Perkins products for pre-mixed or concentrated coolants. Use only Perkins Extender with Extended Life Coolant. Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed. In order to maintain the correct balance between the coolant and the additives, you must maintain the recommended concentration of Extended Life Coolant (ELC). Lowering the proportion of coolant lowers the proportion of additive. This will lower the ability of the coolant to protect the system from pitting, from cavitation, from erosion, and from deposits. NOTICE Do not use a conventional coolant to top-off a cooling system that is lled with Extended Life Coolant (ELC). Do not use standard supplemental coolant additive (SCA). Only use ELC Extender in cooling systems that are lled with ELC. NOTICE When using Perkins ELC, do not use standard SCA's or SCA lters.
Coolant Service Life Coolant Type Perkins ELC Commercial Heavy-Duty Coolant that meets ASTM D6210 Commercial SCA and Water Service Life 6,000 Service Hours or Three Years 3000 Service Hours or Two Years 3000 Service Hours or Two Years
Extended Life Coolant (ELC)

Perkins provides Extended Life Coolant (ELC) for use in the following applications:
Heavy-duty spark ignited gas engines Heavy-duty diesel engines Automotive applications
The anti-corrosion package for ELC is different from the anti-corrosion package for other coolants. ELC is an ethylene glycol base coolant. However, ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite. Perkins ELC has been formulated with the correct amount of these additives in order to provide superior corrosion protection for all metals in engine cooling systems. ELC is available in a 1:1 premixed cooling solution with distilled water. The Premixed ELC provides freeze protection to 36 C (33 F). The Premixed ELC is recommended for the initial ll of the cooling system. The Premixed ELC is also recommended for topping off the cooling system. Containers of several sizes are available. Consult your Perkins dealer or your Perkins distributor for the part numbers.
ELC Cooling System Cleaning

Note: If the cooling system is already using ELC, cleaning agents are not required to be used at the specied coolant change interval. Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage. Clean water is the only cleaning agent that is required when ELC is drained from the cooling system. After the cooling system is drained and after the cooling system is relled, operate the engine while the cooling system ller cap is removed. Operate the engine until the coolant level reaches the normal operating temperature and until the coolant level stabilizes. As needed, add the coolant mixture in order to ll the system to the specied level.
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Changing to Perkins ELC

To change from heavy-duty coolant to the Perkins ELC, perform the following steps: NOTICE Care must be taken to ensure that all uids are contained during performance of inspection, maintenance, testing, adjusting and the repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Dispose of all uids according to local regulations and mandates. 1. Drain the coolant into a suitable container. 2. Dispose of the coolant according to local regulations. 3. Flush the system with clean water in order to remove any debris. 4. Use an appropriate cleaner to clean the system. Follow the instruction on the label. 5. Drain the cleaner into a suitable container. Flush the cooling system with clean water. 6. Fill the cooling system with clean water and operate the engine until the engine is warmed to 49 to 66C (120 to 150F). NOTICE Incorrect or incomplete ushing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely ush the cooling system with clear water. Continue to ush the system until all the signs of the cleaning agent are gone. 7. Drain the cooling system into a suitable container and ush the cooling system with clean water. Note: The cooling system cleaner must be thoroughly ushed from the cooling system. Cooling system cleaner that is left in the system will contaminate the coolant. The cleaner may also corrode the cooling system. 8. Repeat Steps 6 and 7 until the system is completely clean. 9. Fill the cooling system with the Perkins Premixed ELC.
ELC Cooling System Contamination

NOTICE Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life. Use only Perkins Products for premixed or concentrate coolants. Use only Perkins ELC extender with Perkins ELC. Failure to follow these recommendations can result in shortened cooling system component life. ELC cooling systems can withstand contamination to a maximum of ten percent of conventional heavy-duty coolant or SCA. If the contamination exceeds ten percent of the total system capacity, perform ONE of the following procedures:
Drain the cooling system into a suitable container.
Dispose of the coolant according to local regulations. Flush the system with clean water. Fill the system with the Perkins ELC. container according to local regulations. Then, ll the cooling system with premixed ELC. This should lower the contamination to less than 10 percent. Coolant. Treat the system with an SCA. Change the coolant at the interval that is recommended for the conventional Heavy-Duty Coolant.
Drain a portion of the cooling system into a suitable
Maintain the system as a conventional Heavy-Duty
Commercial Heavy-Duty Coolant 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 temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the correct operating temperature. Cooling system problems can develop without water temperature regulators. Check the coolant (glycol concentration) in order to ensure adequate protection against boiling or freezing. Perkins recommends the use of a refractometer for checking the glycol concentration. Perkins engine cooling systems should be tested at 500 hour intervals for the concentration of Supplemental Coolant Additive (SCA).
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Additions of SCA are based on the results of the test. An SCA that is liquid may be needed at 500 hour intervals.
Table 20 is an example for using the equation that is in Table 19.

Table 20
Adding the SCA to Heavy-Duty Coolant at the Initial Fill

Use the equation that is in Table 17 to determine the amount of SCA that is required when the cooling system is initially lled.
Table 17
Example Of The Equation For Adding The SCA To The Heavy-Duty Coolant For Maintenance Total Volume of the Cooling System (V) 15 L (4 US gal) Multiplication Factor 0.014 Amount of SCA that is Required (X) 0.2 L (7 oz)
Equation For Adding The SCA To The Heavy-Duty Coolant At The Initial Fill V 0.045 = X V is the total volume of the cooling system. X is the amount of SCA that is required.
Cleaning the System of Heavy-Duty Coolant Clean the cooling system after used coolant is
drained or before the cooling system is lled with new coolant. contaminated or whenever the coolant is foaming.
Table 18 is an example for using the equation that is in Table 17.

Table 18
Clean the cooling system whenever the coolant is
Example Of The Equation For Adding The SCA To The Heavy-Duty Coolant At The Initial Fill Total Volume of the Cooling System (V) 15 L (4 US gal) Multiplication Factor 0.045 Amount of SCA that is Required (X) 0.7 L (24 oz)
Adding The SCA to The Heavy-Duty Coolant For Maintenance

Heavy-duty coolant of all types REQUIRE periodic additions of an SCA. Test the coolant periodically for the concentration of SCA. For the interval, refer to the Operation and Maintenance Manual, Maintenance Interval Schedule (Maintenance Section). Test the concentration of SCA. Additions of SCA are based on the results of the test. The size of the cooling system determines the amount of SCA that is needed. Use the equation that is in Table 19 to determine the amount of SCA that is required, if necessary:
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.
40 Maintenance Section Maintenance Interval Schedule
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Maintenance Interval Schedule

When Required
Battery - Replace .................................................. Battery or Battery Cable - Disconnect .................. Engine - Clean ...................................................... Engine Air Cleaner Element - Replace ................. Engine Oil Filter (Auxiliary) - Change ................... Engine Oil Sample - Obtain .................................. Fuel System - Prime ............................................. Overhaul (Major) ................................................... Overhaul (Top End) ............................................... Severe Service Application - Check ..................... 43 44 53 53 55 57 60 65 66 67
Governor Actuator - Check ................................... 64 Speed Sensor - Clean/Inspect .............................. 68
Every 5000 Service Hours

Fuel Injector - Inspect/Adjust ................................ 60

Alternator - Inspect ............................................... Engine Oil Pump - Inspect .................................... Fuel Transfer Pump (Lift Pump) - Inspect ............. Starting Motor - Inspect ........................................ Turbocharger - Inspect .......................................... Water Pump - Inspect ........................................... 42 56 63 69 70 72
Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 47
Daily
Cooling System Coolant Level - Check ................ Driven Equipment - Check .................................... Engine Air Cleaner Service Indicator - Inspect ..... Engine Oil Level - Check ...................................... Fuel System Primary Filter/Water Separator Drain ................................................................... Walk-Around Inspection ........................................ 52 52 54 56 62 71
Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 62
Initial 100 Service Hours

Alternator Pulley - Check ...................................... 42 Engine Valve Lash - Inspect/Adjust ...................... 59 Fan Drive Pulley - Check ...................................... 59

Engine Oil Filter (Auxiliary) - Change ................... 55 Engine Oil and Filter - Change ............................. 57
Every 500 Service Hours or 1 Year

Actuator Control Linkage - Lubricate .................... Aftercooler Core - Clean/Test ............................... Aftercooler Core - Inspect ..................................... Battery Electrolyte Level - Check .......................... Belts - Inspect/Adjust/Replace .............................. Belts - Inspect/Adjust/Replace .............................. Engine Crankcase Breather - Clean ..................... Engine Valve Lash - Inspect/Adjust ...................... Fuel System Filter - Replace ................................ Hoses and Clamps - Inspect/Replace .................. Radiator - Clean .................................................... 41 41 42 43 44 46 54 59 61 64 67
Every Year
Cooling System Coolant - Change ....................... 49 Engine Mounts - Inspect ....................................... 55 Engine Protective Devices - Check ...................... 59
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41 Maintenance Section Actuator Control Linkage - Lubricate
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Actuator Control Linkage Lubricate
Aftercooler Core - Clean/Test

1. Remove the core. Refer to the OEM information for the correct procedure.
Personal injury can result from air pressure. Personal injury can result without following proper 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.
Illustration 26 Typical example
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2. Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the fan's air ow. Hold the nozzle approximately 6 mm (.25 inch) away from the ns. Slowly move the air nozzle in a direction that is parallel with the tubes. This will remove debris that is between the tubes. 3. 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. NOTICE Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner. 4. Back ush the core with a suitable cleaner.
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5. Steam clean the core in order to remove any residue. Flush the ns of the aftercooler core. Remove any other trapped debris. 6. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.
The governor actuator (3) is connected to the fuel injectors by external linkages (1) and by internal control rods. The linkages (1) require periodic lubrication of the ball joints (2). Use clean engine oil in order to lubricate the ball joints.
42 Maintenance Section Aftercooler Core - Inspect
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Note: If parts of the aftercooler system are repaired or replaced, a leak test is highly recommended. Personal injury can result from air pressure. Personal injury can result without following proper 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. 7. Dry the core with compressed air. Direct the air in the reverse direction of the normal ow. 8. Inspect the core in order to ensure cleanliness. Pressure test the core. If necessary, repair the core. 9. Install the core. Refer to the OEM information for the correct procedure. 10. After cleaning, run the engine. This will help in the removal of debris and drying of the core. Stop the engine.
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Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.
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Alternator - Inspect
Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and correct battery charging. Check the ammeter (if equipped) during engine operation in order to ensure correct battery performance and/or correct performance of the electrical system. Make repairs, as required. Check the alternator and the battery charger for correct operation. If the batteries are correctly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine. When the engine 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.
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Aftercooler Core - Inspect

Note: Adjust the frequency of cleaning according to the effects of the operating environment. Inspect the aftercooler for these items: damaged ns, corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the aftercooler, if necessary. For air-to-air aftercoolers, use the same methods that are used for cleaning radiators.
Alternator Pulley - Check

1. Isolate the electrical supply to the engine.
Personal injury can result from air pressure. Personal injury can result without following proper 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. After cleaning, start the engine and run the engine. This will help in the removal of debris and drying of the core. Stop the engine. Inspect the ns for damage. Bent ns may be opened with a comb.
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2. Remove the guard (3) in order to gain access to the drive pulley (1) for the alternator (2).
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43 Maintenance Section Battery - Replace
2. Turn off any battery chargers. Disconnect any battery chargers. 3. The NEGATIVE - cable connects the NEGATIVE - battery terminal to the NEGATIVE - terminal on the starting motor. Disconnect the cable from the NEGATIVE - battery terminal. 4. The POSITIVE + cable connects the POSITIVE + battery terminal to the POSITIVE + terminal on the starting motor. Disconnect the cable from the POSITIVE + battery terminal. Note: Always recycle a battery. Never discard a battery. Dispose of used batteries to an appropriate recycling facility. 5. Remove the used battery. 6. Install the new battery. Note: Before the cables are connected, ensure that the engine start switch is OFF. 7. Connect the cable from the starting motor to the POSITIVE + battery terminal. 8. Connect the NEGATIVE - cable to the NEGATIVE - battery terminal.
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3. Tighten the grub screws (4) to a torque of 20 Nm (15 lb ft). 4. Install the guard (3). 5. Restore the electrical supply to the engine.
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Battery - Replace
Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death. Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced.
Battery Electrolyte Level Check

When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries are correctly charged, the ammeter reading should be very near zero, when the engine is in operation.
The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury. 1. Switch the engine to the OFF position. Remove all electrical loads.
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 ller caps. Maintain the electrolyte level to the FULL mark on the battery. If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use articially softened water.
44 Maintenance Section Battery or Battery Cable - Disconnect
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2. Check the condition of the electrolyte with a suitable battery tester. 3. Install the caps. 4. Keep the batteries clean. Clean the battery case with one of the following cleaning solutions:
7. Proceed with necessary system repairs. 8. In order to connect the battery, connect the positive connection before the negative connector.
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Use a solution of 0.1 kg (0.2 lb) baking soda

and 1 L (1 qt) of clean water.
Belts - Inspect/Adjust/Replace (Fan Drive Belts)

Inspection
1. Isolate the electrical supply to the engine. 2. Loosen the fasteners for the air pipes (not shown). 3. Remove the guards (not shown).
Use a solution of ammonium hydroxide.

Thoroughly rinse the battery case with clean water.
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Battery or Battery Cable Disconnect
The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury. 1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads. 2. Disconnect the negative battery terminal. Ensure that the cable cannot contact the terminal. When four 12 volt batteries are involved, two negative connection must be disconnected. 3. Remove the positive connection. 4. Clean all disconnected connection and battery terminals. 5. Use a ne grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not t correctly. Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly. 6. Tape the cable connections in order to help prevent accidental starting.
Illustration 30
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4. Inspect the belts (1) for cracks. Inspect the belts for contamination. If necessary, replace the belts. Refer to Replacement for more information. 5. The belt tension must be checked at position A. Use a suitable spring balance and a suitable straight edge in order to check the belt tension. 6. The belt tension should be 62 N (14 lb) with a maximum deection at position B of 16 mm (0.63 inch). 7. Adjust the belts if the belt tension exceeds 62 N (14 lb). Refer to Adjustment for more information. 8. Tighten the fasteners for the air pipes (not shown) to a torque of 120 Nm (88.5 lb ft).
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45 Maintenance Section Belts - Inspect/Adjust/Replace
9. Install the guards (not shown). 10. Restore the electrical supply to the engine.
Removal of the Fan Drive Belts
Adjustment
1. If necessary, isolate the electrical supply to the engine. Loosen the fasteners for the air pipes and remove the guards.
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1. If necessary, isolate the electrical supply to the engine. Loosen the fasteners for the air pipes and remove the guards. 2. Loosen the locknut (4).
Illustration 31
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2. Loosen the locknut (4). 3. Rotate the rod (3) in order to achieve the correct tension of belts (1). Refer to Inspection for the correct specication. 4. Tighten the locknut (4) to a torque of 120 Nm (88.5 lb ft). 5. If necessary, restore the electrical supply to the engine. Tighten the fasteners for the air pipes and install the guards.
3. Rotate the rod (3) until the pulley (2) is toward the center of the engine. 4. Remove the belts (1).
Installation of the Fan Drive Belts

1. Install new belts (1) over the pulleys. 2. Rotate the rod (3) in order to achieve an initial tension of 77 N (17 lb). The total deection should not exceed 16 mm (0.63 inch). 3. Tighten the locknut (4) to a torque of 120 Nm (88.5 lb ft). 4. Rotate the pulleys for the fan drive belts three to four revolutions in order to ensure that the fan drive belts are correctly installed. Ensure that the tension is still 77 N (17 lb). 5. If necessary, restore the electrical supply to the engine. Tighten the fasteners for the air pipes and install the guards. 6. Operate the engine for 15 to 20 minutes. Refer to Operation and Maintenance Manual, Starting the Engine for the correct procedure.
Replacement
Note: Fan drive belts must be replaced as a set. Do not replace individual belts.
46 Maintenance Section Belts - Inspect/Adjust/Replace
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7. Stop the engine. Refer to Operation and Maintenance Manual, Stopping the Engine for the correct procedure. 8. If necessary, isolate the electrical supply to the engine. Loosen the fasteners for the air pipes and remove the guards. 9. Loosen the locknut (4). 10. Rotate the rod (3) in order to achieve a nal tension of 62 N (14 lb). The total deection should not exceed 16 mm (0.63 inch). 11. Tighten the locknut (4) to a torque of 120 Nm (88.5 lb ft). 12. If necessary, restore the electrical supply to the engine. Tighten the fasteners for the air pipes and install the guards.
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Illustration 34
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4. Apply 15.6 N (3.5 lb) of pressure at point (X). The total deection should not exceed 1.5 mm (0.06 inch). Replace the belt if the total deection exceeds 1.5 mm (0.06 inch). Refer to Replacement for more information. 5. Install the guard (3) and bolts (2). 6. Restore the electrical supply to the engine.
Belts - Inspect/Adjust/Replace (Alternator Belt)

Inspection
Adjustment
The alternator belt is a toothed belt. The belt tension is not adjustable. The belt does not require a preload. Light tension will ensure that the belt is a snug t on the pulleys.
Replacement
Removal of the Alternator Belt
1. If necessary, Isolate the electrical supply to the engine and remove the guards.
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2. Remove the bolts (2) and remove the guard (3). 3. Inspect the belt (1) for cracks. Inspect the belt for contamination. If necessary, replace the belt. Refer to Replacement for more information.
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47 Maintenance Section Cooling System Coolant (ELC) - Change
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Cooling System Coolant (ELC) - Change

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Dispose of all uids according to Local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Clean the cooling system and ush the cooling system before the recommended maintenance interval if the following conditions exist:
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2. Remove nut (5) and bolt (4). 3. Loosen nut (7) and push the alternator (6) toward the engine. 4. Remove the belt (1).
The engine overheats frequently. Foaming of the coolant is observed. The oil has entered the cooling system and the
coolant is contaminated. coolant is contaminated.
Installation of the Alternator Belt

1. Install the belt (1) over the pulleys. Note: Ensure that the teeth on the belt are engaged with the teeth on the pulleys. 2. Pull the alternator (6) away from the engine. Install bolt (4) and nut (5). 3. Tighten nuts (5) and (7). 4. Check the tension of the belt. Refer to Inspection for the correct procedure. 5. If necessary, restore the electrical supply to the engine and install the guards.
The fuel has entered the cooling system and the

Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced. Note: Inspect the water pumps and the water temperature regulators after the cooling system has been drained. This is a good opportunity to replace the water pumps, the water temperature regulators, and the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
48 Maintenance Section Cooling System Coolant (ELC) - Change
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4. Open the drain cocks or remove the drain plugs (3) in the oil coolers.
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1. Stop the engine and allow the engine to cool. Loosen the cooling system ller cap (1) slowly in order to relieve any pressure. Remove the cooling system ller cap.
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5. Open the drain cocks or remove the drain plugs (5) in the aftercoolers. 6. Allow the coolant to drain. NOTICE Dispose of used engine coolant or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Perkins to reclaim the coolant. For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor.
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2. Open the drain cock or remove the drain plug (2) in the cylinder block. 3. Open the drain cock or remove the drain plug on the radiator.
Flush
1. Flush the cooling system with clean water in order to remove any debris. 2. Close the drain cock or install the drain plug (2) in the cylinder block. Close the drain cock or install the drain plug on the radiator. Close the drain cocks or install the drain plugs (3) in the oil coolers. Close the drain cocks or install the drain plugs (5) in the aftercoolers. NOTICE Do not ll the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.
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Cooling system air locks may result in engine damage.
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49 Maintenance Section Cooling System Coolant - Change
3. Fill the cooling system with clean water. If equipped, loosen the vent screws (4) in the aftercoolers. Fill the cooling system until coolant free of air ows from the vent screws. Tighten the vent screws securely. Install the cooling system ller cap (1). 4. Start the engine. Run the engine until the temperature reaches 49 to 66 C (120 to 150 F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system ller cap (1) slowly in order to relieve any pressure. Remove the cooling system ller cap. Open the drain cock or remove the drain plug (2) in the cylinder block. Open the drain cock or remove the drain plug on the radiator. Open the drain cocks or remove the drain plugs (3) in the oil coolers. Open the drain cocks or remove the drain plugs (5) in the aftercoolers. Allow the water to drain. Flush the cooling system with clean water.
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5. Clean the cooling system ller cap (1) and inspect the seal (2). If the seal is damaged, discard the old ller cap and install a new ller cap. If the seal is not damaged, use a suitable pressurizing pump in order to pressure test the ller cap. The correct pressure is stamped on the face of the ller cap. If the ller cap does not retain the correct pressure, replace the ller cap. Install the cooling system ller cap. 6. Start the engine and run the engine. Inspect the cooling system for leaks. Ensure that the cooling system operates at the correct temperature.
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Fill
1. Close the drain cock or install the drain plug (2) in the cylinder block. Close the drain cock or install the drain plug on the radiator. Close the drain cocks or install the drain plugs (3) in the oil coolers. Close the drain cocks or install the drain plugs (5) in the aftercoolers. NOTICE Do not ll 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 Coolant (ELC). Refer to the Operation and Maintenance Manual, Fluid Recommendations topic (Maintenance Section) for more information on cooling system specications. Do not install the cooling system ller cap (1). 3. Start the engine. Run the engine in order to purge the air from the cavities of the engine block. Stop the engine. 4. Check that the coolant level is within 25 mm (1.0 inch) of the bottom of the ller pipe.
Cooling System Coolant Change (Inhibitor)

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Dispose of all uids according to Local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Clean the cooling system and ush the cooling system before the recommended maintenance interval if the following conditions exist:
The engine overheats frequently. Foaming of the coolant is observed.
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The oil has entered the cooling system and the

coolant is contaminated. coolant is contaminated.
The fuel has entered the cooling system and the

Note: When the cooling system is cleaned, only clean water is needed when the inhibitor is drained and replaced. Note: Inspect the water pumps and the water temperature regulators after the cooling system has been drained. This is a good opportunity to replace the water pumps, the water temperature regulators, and the hoses, if necessary.
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Drain
2. Open the drain cock or remove the drain plug (2) in the cylinder block. Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 3. Open the drain cock or remove the drain plug on the radiator.
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4. Open the drain cocks or remove the drain plugs (3) in the oil coolers.
1. Stop the engine and allow the engine to cool. Loosen the cooling system ller cap (1) slowly in order to relieve any pressure. Remove the cooling system ller cap.
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If equipped, loosen the vent screws (4) in the aftercoolers. Fill the cooling system until coolant free of air ows from the vent screws. Tighten the vent screws securely. Install the cooling system ller cap (1). 4. Start the engine. Run the engine until the temperature reaches 49 to 66 C (120 to 150 F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system ller cap (1) slowly in order to relieve any pressure. Remove the cooling system ller cap. Open the drain cock or remove the drain plug (2) in the cylinder block. Open the drain cock or remove the drain plug on the radiator. Open the drain cocks or remove the drain plugs (3) in the oil coolers. Open the drain cocks or remove the drain plugs (5) in the aftercoolers. Allow the water to drain. Flush the cooling system with clean water.
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Fill
1. Close the drain cock or install the drain plug (2) in the cylinder block. Close the drain cock or install the drain plug on the radiator. Close the drain cocks or install the drain plugs (3) in the oil coolers. Close the drain cocks or install the drain plugs (5) in the aftercoolers. NOTICE Do not ll 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.
5. Open the drain cocks or remove the drain plugs (5) in the aftercoolers. 6. Allow the coolant to drain. NOTICE Dispose of all uids according to local regulations and mandates. When you recycle used engine coolant for reuse in engine cooling systems, the full distillation procedure is the only method acceptable by Perkins Engines Company LTD to reclaim the coolant.
Flush
1. Flush the cooling system with clean water in order to remove any debris. 2. Close the drain cock or install the drain plug (2) in the cylinder block. Close the drain cock or install the drain plug on the radiator. Close the drain cocks or install the drain plugs (3) in the oil coolers. Close the drain cocks or install the drain plugs (5) in the aftercoolers. NOTICE Do not ll 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. 3. Fill the cooling system with clean water.
2. Fill the cooling system with water and inhibitor. Refer to the Operation and Maintenance Manual, Fluid Recommendations topic (Maintenance Section) for more information on cooling system specications. Do not install the cooling system ller cap (1). 3. Start the engine. Run the engine in order to purge the air from the cavities of the engine block. Stop the engine. 4. Check that the coolant level is within 25 mm (1.0 inch) of the bottom of the ller pipe.
Illustration 45
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52 Maintenance Section Cooling System Coolant Level - Check
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5. Clean the cooling system ller cap (1) and inspect the seal (2). If the seal is damaged, discard the old ller cap and install a new ller cap. If the seal is not damaged, use a suitable pressurizing pump in order to pressure test the ller cap. The correct pressure is stamped on the face of the ller cap. If the ller cap does not retain the correct pressure, replace the ller cap. Install the cooling system ller cap. 6. Start the engine and run the engine. Inspect the cooling system for leaks. Ensure that the cooling system operates at the correct temperature.
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Illustration 47
g01239656
Cooling System Coolant Level - Check
3. Clean the cooling system ller cap (1) and inspect the seal (2). If the seal is damaged, discard the old ller cap and install a new ller cap. If the seal is not damaged, use a suitable pressurizing pump in order to pressure test the ller cap. The correct pressure is stamped on the face of the ller cap. If the ller cap does not retain the correct pressure, replace the ller cap. Install the cooling system ller cap. 4. Inspect the cooling system for leaks.
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Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Check the coolant level when the engine is stopped and cool.
Driven Equipment - Check

Refer to the OEM specications for more information on the following maintenance recommendations for the driven equipment:
Inspection Adjustment Lubrication Other maintenance recommendations

Perform any maintenance for the driven equipment which is recommended by the OEM.
Illustration 46
g01211179
1. Remove the cooling system ller cap (1) slowly in order to relieve pressure. 2. Maintain the coolant level within 25 mm (1.0 inch) of the bottom of the ller pipe.
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53 Maintenance Section Engine - Clean
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Engine - Clean
Engine Air Cleaner Element Replace

NOTICE Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet. NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine. Renew the air lter elements if the service indicators are triggered. Refer to Operation and Maintenance Manual, Engine Air cleaner Service Indicator Inspect for more information. Some engines are equipped with air intake precleaners. Clean the precleaners before maintenance is performed on the air lters. Ensure that dirt does not enter the housing of the air cleaner.
Personal injury or death can result from high voltage. Moisture can create paths of electrical conductivity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls DO NOT OPERATE. NOTICE Accumulated grease and oil on an engine is a re hazard. Keep the engine clean. Remove debris and uid spills whenever a signicant quantity accumulates on the engine. NOTICE Water or condensation can cause damage to generator components. Protect all electrical components from exposure to water. NOTICE Failure to protect some engine components from washing may make your engine warranty invalid. Allow the engine to cool for one hour before washing the engine. Periodic cleaning of the engine is recommended. A clean engine provides the following benets:
Easy detection of uid leaks Maximum heat transfer characteristics Ease of maintenance
Note: Caution must be used in order to prevent electrical components from being damaged by excessive water when the engine is cleaned. Pressure washers and steam cleaners should not be directed at any electrical connectors or the junction of cables into the rear of the connectors. Avoid electrical components such as the alternator, the starting motors, and the ECU.
Illustration 48
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1. Loosen securing clamp (3) and remove cover (4) for housing (1). 2. Remove the old element (2) from the housing (1). Discard the old element. Note: Ensure that dirt does not enter the housing.
54 Maintenance Section Engine Air Cleaner Service Indicator - Inspect
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3. Install a new element (2) into the housing (1). Install the cover (4) and tighten securing clamp (3).
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Service Indicator Reset
Engine Air Cleaner Service Indicator - Inspect

Service Indicator Check
Check the service indicators. Replace the air lter elements if one of service indicators has been triggered.
Illustration 51
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Once the service indicator has been triggered and when the air lter element has been replaced, the service indicator must be reset. In order to reset the service indicator (1), press the button (2). If the service indicator does not reset easily, the service indicator should be replaced. Note: The service indicator may need to be replaced frequently in environments that are severely dusty.
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Illustration 49
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When the air lter element is in a serviceable condition, the center section of the service indicator (1) is clear.
Engine Crankcase Breather Clean

The engine crankcase breathers are mounted on the side of the water regulators. 1. Isolate the electrical supply to the starting motor.
Illustration 50
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When the air lter element requires replacement, the center section of the service indicator (1) is red.
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55 Maintenance Section Engine Mounts - Inspect
Loose bolts Deterioration of the isolators

Ensure that the mounting bolts are tightened to the correct torque. Ensure that the isolators are free of oil and contamination. Inspect the isolators for deterioration. Ensure that the bolts for the isolators are tightened to the correct torque. Replace any isolator that shows deterioration. For more information, see the literature that is provided by the OEM of the isolators.
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Engine Oil Filter (Auxiliary) Change

g02775881
2. Remove the wing nut (1) and the cover (2). 3. Remove the lter elements (3) from the breather body (5). 4. Clean the lter elements (3) and dry the lter elements. Inspect the lter elements for damage or deterioration. If necessary, replace the lter elements. 5. Install the lter elements (3) to the breather body (5). 6. Ensure that the seal in the cover (2) is free from damage. If necessary, replace the seal. 7. Align the cover (2) with the dowel (4). Install the cover to the breather body (5). 8. Install the wing nut (1). Tighten the wing nut securely. 9. Restore the electrical supply to the starting motor.
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Note: Refer to the Operation and Maintenance Manual, Engine Oil Sample - Obtain before performing maintenance.
Change the Filter with the Engine in Operation
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Engine Mounts - Inspect

Misalignment of the engine and the driven equipment will cause extensive damage. Excessive vibration can lead to misalignment. Excessive vibration of the engine and the driven equipment can be caused by the following conditions:
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Improper mounting
56 Maintenance Section Engine Oil Level - Check
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The changeover valve (1) has three positions.
(A) The oil ow is to both oil lters. (B) The oil ow is to the left-hand oil lter. (C) The oil ow is to the right-hand oil lter.
1. Rotate the changeover valve to position B. By using a suitable tool (2), remove the right-hand oil lter. Note: Oil ow direction (D and E ). 2. Ensure that the sealing face on the housing is clean. Fill the new oil lter with clean engine oil. Install the new oil lter. Rotate the changeover valve to position A. Check for oil leaks. 3. Rotate the changeover valve to position C. By using a suitable tool, remove the left-hand oil lter. 4. Ensure that the sealing face on the housing is clean. Fill the new oil lter with clean engine oil. Install the new oil lter. Apply hand pressure only in order to install the oil lter. Rotate the changeover valve to position A. Check for oil leaks. 5. Clean any spillage of engine oil.
Illustration 55
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Illustration 54
g01236968
(Y) Min mark. (X) Max mark.
Engine Oil Level - Check
1. Maintain the oil level between the Min mark (Y) and the Max mark (X) on the engine oil level gauge (2). Do not ll the oil pan above the Max mark (X). 2. If necessary, remove the oil ller cap (1) and add oil. Clean the oil ller cap. Install the oil ller cap.
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. NOTICE Perform this maintenance with the engine stopped. Note: After the engine has been switched OFF, wait for ten minutes in order to allow the engine oil to drain to the oil pan before checking the oil level. NOTICE Operating your engine when the oil level is above the Max mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into the oil reduces the oil's lubricating characteristics and could result in the loss of power.
Engine Oil Pump - Inspect

A failed engine oil pump may result in a seizure of the crankshaft. Remove the engine oil pump and disassemble the engine oil pump. Refer to Operation Manual TSL4165 for more information. Inspect the components of engine oil pump for wear and for damage. Refer to Operation Manual TSL4165 for more information. Replace any components that are worn or damaged. Alternatively, replace the engine oil pump.
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57 Maintenance Section Engine Oil Sample - Obtain
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The amount of oil that has been added since the

last oil change Ensure that the container for the sample is clean and dry. Also ensure that the container for the sample is clearly labelled.
Engine Oil Sample - Obtain
The condition of the engine lubricating oil should be checked at regular intervals as part of the preventive maintenance program.
To ensure that the sample is representative of the oil in the crankcase, obtain a warm, well mixed oil sample. To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean. The sample can be checked for the following: the quality of the oil, the existence of any coolant in the oil, the existence of any ferrous metal particles in the oil, and the existence of any nonferrous metal particles in the oil.
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Initiating an Oil analysis Program

The First 500 Hours
Oil analysis in the rst 500 hours will show higher levels of iron and copper than acceptable parameters. As the engine continues to operate the levels will drop within the specied parameters.
Every 250 Hours

An oil sample should be obtained at 250 hour intervals. A trend can be established by analyzing the results of the oil sampling. Each individual operator can develop a service program for the engine. Note: Perkins Engines Stafford must agree to the maintenance schedule. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Dispose of all uids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Do not drain the engine lubricating oil when the engine is cold. As the engine lubricating oil cools, suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed with draining cold oil. Drain the oil pan with the engine stopped. Drain the oil pan with the oil warm. This draining method allows the waste particles that are suspended in the oil to be drained properly.
Engine Oil and Filter - Change
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. The oil sample must be taken from the mean level in the engine oil pan. Do not take an oil sample from the drain plug. 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 since
the last oil change
58 Maintenance Section Engine Oil and Filter - Change
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Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil.
Drain the Engine Lubricating Oil
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1. Place a suitable container below the engine oil pan. Remove the drain plug (3). Allow the engine oil to drain. Note: Ensure that the vessel that will be used is large enough to collect the waste oil. 2. Remove the sealing washer from the drain plug (3). Discard the sealing washer. 3. Install a new sealing washer to the drain plug (3). Install the drain plug to the engine oil pan. Tighten the plug to a torque of 68 Nm (50 lb ft).
1. Use Tooling (A) in order to remove the oil lters (4). 2. Ensure that the sealing face of the lter base (6) is clean. 3. Lubricate the sealing rings (5) with clean engine oil. Fill the oil lters with clean engine oil. Ensure that the engine oil that is added to the oil lters has not been contaminated. Install the new oil lters (4). Note: Apply hand pressure only in order to tighten the oil lters.
Replace the Oil Filter

Table 21
Fill the Oil Pan

Refer to Operation and Maintenance Manual, Fluid Recommendations for information on suitable oils.
Qty 1
Required Tools Tool A Part Number Part Name Strap Wrench
1. Remove the oil ller cap. 2. Fill the oil pan with the correct amount of new engine lubricating oil. Refer to Operation and Maintenance Manual, Rell Capacities for more information. NOTICE If equipped with an auxiliary oil lter system or a remote lter system, follow the OEM or the lter manufacture's recommendations. Under lling or over lling the crankcase with oil can cause engine damage. Note: Before starting the engine, crank the engine on the starter in order to obtain oil pressure.
NOTICE Perkins oil lters are manufactured to Perkins Engine Company LTD specications. Use of an oil lter that is not recommended by Perkins Engine Company LTD could result in severe damage to the engine. Large particles from unltered engine oil will cause damage to the engine. Do not use oil lters that are not recommended by Perkins Engine Company LTD. Note: All six oil lters must be changed as a set.
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59 Maintenance Section Engine Protective Devices - Check
3. Start the engine and run the engine for 2 minutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil lters are lled. Inspect the oil lters for oil leaks. 4. Stop the engine and allow the oil to drain back to the oil pan for a minimum of 10 minutes.
To prevent damage to the engine, only authorized service personnel or your Perkins dealer should perform the tests.
Visual Inspection
Visually check the condition of all gauges, sensors and wiring. Look for wiring and components that are loose, broken, or damaged. Damaged wiring or components should be repaired or replaced immediately.
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Engine Valve Lash Inspect/Adjust (Valves and Valve Bridges)

Illustration 58 (Y) Min mark. (X) Max mark.
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5. Remove the engine oil level gauge (2) in order to check the oil level. Maintain the oil level between the MIN and MAX marks on the engine oil level gauge.
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NOTICE Only qualied service personel should perform this maintenance. Refer to the Service Manual or your authorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure. Operation of Perkins engines with incorrect valve lash can reduce engine efciency, and also reduce engine component life.
Engine Protective Devices Check

Alarms and shutoffs must function properly. Alarms provide timely warning to the operator. Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine protective devices are in good working order during normal operation. Malfunctions must be simulated in order to test the engine protective devices. A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints. Ensure that the engine protective devices are functioning properly. NOTICE During testing, abnormal operating conditions must be simulated. The tests must be performed correctly in order to prevent possible damage to the engine. Ensure that the engine can not be started while this maintenance is being performed. To help prevent possible injury, do not use the starting motor to turn the ywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance. Note: The valve bridges must be equalized before the valve lash is adjusted. Refer to Systems Operation, Testing and Adjusting, Valve Lash - Adjust for the correct procedure.
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Fan Drive Pulley - Check

60 Maintenance Section Fuel Injector - Inspect/Adjust
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Fuel Injector - Inspect/Adjust

NOTICE Only qualied service personnel should perform this maintenance. Refer to the Service Manual or your authorized Perkins distributor for the complete procedure in order to inspect or adjust the fuel injectors. Operation of Perkins engines with fuel injectors that have not been inspected or adjusted can reduce engine efciency, and also reduce engine component life. Refer to Systems Operation, Testing and Adjusting, Fuel Injector Adjustment for the correct procedures to inspect and adjust the fuel injectors.
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2. Remove the guards (not shown) in order to gain access to the fan drive pulley (1).
Fuel System - Prime

If air enters the fuel system, the air must be purged from the fuel system before the engine can be started. Air can enter the fuel system when the following events occur:
The fuel day tank is empty or partially drained. The low pressure fuel lines are disconnected. A leak exists in the low pressure fuel system. The fuel lter has been replaced.
Illustration 60
g01238305
Use the following procedures in order to remove air from the fuel system. Note: Do not bleed the fuel system from the water separator (if equipped). 1. Ensure that the fuel system is in working order. Check that the fuel supply from the fuel day tank is in the ON position.
3. Tighten the grub screws (2) to a torque of 90 Nm (66 lb ft). 4. Install the guards (not shown). 5. Restore the electrical supply to the engine.
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61 Maintenance Section Fuel System Filter - Replace
8. Operate the handle (4) until fuel that is free of air ows from the connection (5). 9. Tighten the connection (5). 10. Loosen connections (6) and (8). 11. Operate the handle (4) until fuel that is free of air ows from the connection (6) and (8). 12. Tighten connections (6) and (8). One cylinder is now primed. An amount of fuel will have reached the remaining cylinders. 13. Push the handle and twist the handle in order to return the priming pump to the locked position. 14. Operate the starting motor and crank the engine. After the engine has started, run the engine for a minimum of ve minutes.
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Note: Operating the engine for this period of time will purge the remaining air from the fuel system.
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2. Place a suitable container below the tee piece (2) in order to catch any fuel that might be spilled. Note: Clean up any spillage of fuel immediately. 3. Loosen the connection (1) at the tee piece (2). 4. Unscrew the handle (4) in order to operate the fuel priming pump (3). Pump the handle until fuel that is free of air ows from the tee piece (2). 5. Tighten the connection (1) on the tee piece (2).
Fuel System Filter - Replace
Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. To help prevent possible injury, turn the start switch off when changing fuel lters or water separator elements. Clean up fuel spills immediately. NOTICE Ensure that the engine is stopped before any servicing or repair is performed.
Fuel Filter with Water Separator

Table 22
Required Tools
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Tool A
Part Number -
Part Name Strap Wrench
Qty 1
6. Place a suitable container below the rear of the fuel rail (7) on A bank, in order to catch any fuel that might be spilled. Note: Clean up any spillage of fuel immediately. 7. Loosen the connection (5).
1. Isolate the fuel supply to the engine. 2. Place a suitable container under the fuel lter in order to catch any fuel that might spill. Note: Clean up any spilled fuel immediately.
62 Maintenance Section Fuel System Primary Filter/Water Separator - Drain
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NOTICE Ensure that the engine is stopped before any servicing or repair is performed. NOTICE The water separator can be under suction during normal engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system. 1. Place a suitable container under the water separator in order to catch any fuel that might spill. Note: Clean up any spilled fuel immediately.
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3. Loosen the drain plug (2). Allow the uid to drain into the container. 4. Clean the outside of the fuel lter. Use Tooling (A) in order to remove the canister (1). Dispose of the canister in accordance with local regulations. 5. Lubricate the O ring seal on the new canister with clean fuel oil. Install the new canister. Tighten the canister by hand. 6. Tighten the drain plug (2). Use hand pressure only. 7. Remove the container and dispose of the fuel in accordance with local regulations. 8. Restore the fuel supply to the engine. 9. Prime the fuel system. Refer to the Operation and Maintenance Manual, Fuel System - Prime for more information. 10. Start the engine and run the engine. Check the fuel system for leaks.
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2. Loosen the drain plug (1). Allow the uid to drain into the container until clean fuel can be seen. 3. Tighten the drain plug (1). Use hand pressure only. Dispose of the drained uid in accordance with local regulations.
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Fuel System Primary Filter/Water Separator - Drain
Fuel Tank Water and Sediment - Drain

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Dispose of all uids according to local regulations and mandates.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. To help prevent possible injury, turn the start switch off when changing fuel lters or water separator elements. Clean up fuel spills immediately.
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63 Maintenance Section Fuel Transfer Pump (Lift Pump) - Inspect
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 lled. Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.
If a bulk storage tank has been relled or moved recently, allow adequate time for the sediment to settle before lling the engine fuel tank. Internal bafes in the bulk storage tank will also help trap sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel. When possible, water separators should be used.
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Fuel Transfer Pump (Lift Pump) - Inspect

Visually inspect the lift pump for leaks. The lift pump is not a serviceable item. Replace a lift pump that is faulty. Replace a lift pump that leaks.
Drain the Water and the Sediment

Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks. Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve. Check the fuel daily. Allow ve minutes after the fuel tank has been lled before draining water and sediment from the fuel tank. Fill the fuel tank after operating the engine in order to drive out moist air. This will help prevent condensation. Do not ll the tank to the top. The fuel expands as the fuel gets warm. The tank may overow. Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system lter is important.
Replacement of the Lift Pump

Removal of the Lift Pump
1. Isolate the fuel supply to the lift pump. 2. Place a suitable container below the lift pump in order to catch any fuel that might be spilled. Note: Clean up any spillage of fuel immediately.
Fuel Storage Tanks

Drain the water and the sediment from the fuel storage tank at the following intervals:
Weekly Service intervals Rell of the tank

This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank.
Illustration 65
g01280509
3. Remove the fuel priming pump (5). 4. Disconnect fuel line (3) and the connection (1). Cap the fuel line with a suitable cap. 5. Remove the two nuts (4).
64 Maintenance Section Governor Actuator - Check
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6. Remove the fuel lift pump (2). 7. Remove the joint from the lift pump (2). Discard the joint.
If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a uid penetration hazard. Refer to Operation and Maintenance Manual, General hazard Information. Inspect all hoses for leaks that are caused by the following conditions:
Installation of the Lift Pump

1. Install a new joint to the lift pump (2). 2. Align the drive for the lift pump (2). Install the lift pump. Note: Ensure that the oil seal is not damaged as the lift pump is installed. 3. Install the nuts (4). Tighten the nuts to a torque of 25 Nm (18 lb ft). 4. Remove the cap from the fuel line (3). Connect the fuel line and the connection (1). Tighten the fuel line and the connection to a torque of 50 Nm (37 lb ft). 5. Fit the fuel priming pump (5) to the lift pump (2). 6. Restore the fuel supply to the lift pump. 7. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, Fuel System - Prime.
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Cracking Softness Loose clamps

Replace hoses that are cracked or soft. Tighten any loose clamps. Check for the following conditions:
End ttings that are 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. Due to extreme temperature changes, the hose will harden. Hardening of the hoses will cause hose clamps to loosen. This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps. Each installation application can be different. The differences depend on the following factors:
Governor Actuator - Check

In order for the governor to operate correctly, the control box must be calibrated to the actuator. The feedback parameters from the control box must correspond to the 0% and the 100% positions on the actuator. Carry out a periodic calibration check of the governor system. Refer to Special Instruction, Pandoras Digital Governor for more information.
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Type of hose
Hoses and Clamps Inspect/Replace
Type of tting material Anticipated expansion and contraction of the hose Anticipated expansion and contraction of the
ttings
Replace the Hoses and the Clamps

Contact with high pressure fuel may cause uid penetration and burn hazards. High pressure fuel spray may cause a re hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. Refer to the OEM information for further information on removing and replacing fuel hoses (if equipped).
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65 Maintenance Section Overhaul (Major)
The coolant system and the hoses for the coolant system are not usually supplied by Perkins. The following text describes a typical method of replacing coolant hoses. Refer to the OEM information for further information on the coolant system and the hoses for the coolant system.
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Overhaul (Major)
Scheduling a Major Overhaul
The need for a major overhaul is determined by several factors:
Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Stop the engine. Allow the engine to cool. 2. Loosen the cooling system ller cap slowly in order to relieve any pressure. Remove the cooling system ller cap. Note: Drain the coolant into a suitable, clean container. The coolant can be reused. 3. Drain the coolant from the cooling system to a level that is below the hose that is being replaced. 4. Remove the hose clamps. 5. Disconnect the old hose. 6. Replace the old hose with a new hose. 7. Install the hose clamps with a torque wrench. Note: For the correct coolant, see this Operation and Maintenance Manual, Fluid Recommendations. 8. Rell the cooling system. Refer to the OEM information for further information on relling the cooling system. 9. Clean the cooling system ller cap. Inspect the cooling system ller cap's seals. Replace the cooling system ller cap if the seals are damaged. Install the cooling system ller cap. 10. Start the engine. Inspect the cooling system for leaks.
An increase of oil consumption An increase of crankcase blowby A decrease and variation of cylinder compression
Other factors must also be considered for determining a major overhaul:
The service hours of the engine The wear metal analysis of the lube oil An increase in the levels of noise and vibration
An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced. An increase in the levels of noise and vibration indicates that rotating parts require service. Note: It is possible for oil analysis to indicate a decrease of wear metals in the lube oil. The cylinder liners may be worn so that polishing of the bore occurs. Also, the increased use of lube oil will dilute the wear metals. Monitor the engine as the engine accumulates service hours. Consult Perkins Engines Stafford about scheduling a major overhaul. Note: The driven equipment may also require service when the engine is overhauled. Refer to the literature that is provided by the OEM of the driven equipment.
Major Overhaul Information

During a major overhaul, all of the bearings, seals, joints, and components that wear should be disassembled. The parts should be cleaned. The parts should then be inspected. If necessary, the parts should be replaced. The crankshaft should be inspected and measured for wear. The crankshaft may require regrinding. Alternatively, the crankshaft may be replaced.
Inspecting Components
Inspect the following components during a major overhaul.
66 Maintenance Section Overhaul (Top End)
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Engine mounted aftercoolers Camshafts Camshaft followers Connecting rods and bearings Crankshaft and bearings Gear train Inlet air piping Oil cooler Pistons and rings Cylinder liners
Replace the crankshaft vibration damper.
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1. Remove the rocker covers. 2. Refer to Systems Operation, Testing and Adjusting, Valve Lash - Adjust. 3. On all engine cylinders, record the clearance before any adjustments are made. 4. Set the valve bridges. 5. Adjust the valve lash to 0.4 mm (0.016 inch). The recorded values can be used to identify any excessive valve seat wear on individual valves. The recorded values can be used to schedule a top end overhaul. An example of recorded valve lash
Table 23
Recorded clearances on A1 cylinder Hours 500 1000 Inlet 0.4mm 0.4 0.35 0.35 0.3 0.25 0.25 0.25 Exhaust 0.4mm 0.4 0.35 0.35 0.3 0.3 0.35 0.3
Total valve wear
Overhaul (Top End)

Scheduling a Top End Overhaul
Top end overhauls should be scheduled according to the recession of the valve stems. This measurement provides an accurate indication of the rate of valve wear. This measurement can be used to predict when a cylinder head requires replacement. Note: Generally, cylinder heads wear out at different rates. In some cases, servicing the cylinder heads at different times may be the most economic decision. This depends on the valve stem projection of the individual cylinders. However, this decision must include the costs of additional downtime that is caused by this procedure. Perform an economic analysis in order to determine if cylinder heads should be serviced as a group or divided into smaller groups.
Inlet 0 0 0.05 0.1 0.2 0.35 0.5 0.65
Exhaust 0 0 0.05 0.1 0.2 0.3 0.35 0.45
1500 2000 2500 3000 3500 4000
After 4000 hours running, the valve seat wear on the inlet is 0.65 mm (0.026 inch) and the exhaust is 0.45 mm (0.018 inch). Note: Maximum permitted valve seat wear is 1.00 mm (0.040 inch). In this example, the valves are still serviceable after 4000 hours running. When the valves approach the maximum wear limit, the rockers can be removed and a measurement from the cylinder head face to the top of the valve stems can be taken. When a new valve is installed the protrusion of the valve stem would be 29.75 mm (1.171 inch). therefore, a maximum wear limit would be 30.75 mm (1.211 inch).
Top End Overhaul Information

A top end overhaul involves servicing the cylinder heads. During a top end overhaul, one piston should be removed. Inspect the piston, piston rings, and the cylinder liner. The condition of these components will determine the period of the major overhaul. Refer to Service Manual for more information.
Monitoring Valve Seat Wear

Every 500 service hours record the valve lash. The monitoring of the valve seat wear should be carried out before any adjustment of the valve lash.
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67 Maintenance Section Radiator - Clean
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Radiator - Clean
Note: Adjust the frequency of cleaning according to the effects of the operating environment. Inspect the radiator for these items: Damaged ns, corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the radiator, if necessary.
Severe Service Application Check

Severe service is the application of an engine that exceeds the current published standards for that engine. Perkins maintains standards for the following engine parameters:
Performance such as power range, speed range,

and fuel consumption Personal injury can result from air pressure. Personal injury can result without following proper 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. Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction to the fan's air ow. Hold the nozzle approximately 6 mm (0.25 inch) away from the radiator ns. Slowly move the air nozzle in a direction that is parallel 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 detergent and hot water. Thoroughly rinse the core with clean water. After cleaning the radiator, start the engine. Run the engine. This will help in the removal of debris and the drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary. Inspect the ns for damage. Bent ns may be opened with a comb. Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.
Fuel quality Operational Altitude Maintenance intervals Oil selection and maintenance Coolant type and maintenance Environmental qualities Installation The temperature of the uid in the engine
Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the dened parameters. Severe service operation can accelerate component wear. Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensure maximum reliability and retention of full service life. Due to individual applications, it is not possible to identify all of the factors which can contribute to severe service operation. Consult your Perkins dealer or your Perkins distributor for the unique maintenance that is necessary for the engine. The operating environment, incorrect operating procedures and incorrect maintenance procedures can be factors which contribute to a severe service application.
68 Maintenance Section Speed Sensor - Clean/Inspect
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Environmental Factors
Ambient temperatures The engine may be exposed to extended operation in extremely cold environments or hot environments. Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures. Extremely hot intake air reduces engine performance. Quality of the air The engine may be exposed to extended operation in an environment that is dirty or dusty, unless the equipment is cleaned regularly. Mud, dirt and dust can encase components. Maintenance can be very difcult. The buildup can contain corrosive chemicals. Buildup Compounds, elements, corrosive chemicals and salt can damage some components. Altitude Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application. Necessary adjustments should be made.
Table 24
Required Tools Tool A Part Number SE253 Part Name Crankshaft Turning Tool Qty 1
Engine Speed Sensor

The crankshaft position sensor is located in the right hand side of the ywheel housing. 1. Isolate the electrical supply to the engine.
Incorrect Operating Procedures

Extended operation at low idle Frequent hot shutdowns Operating at excessive loads Operating at excessive speeds Operating outside the intended application
g01237852
Incorrect Maintenance Procedures

Extending the maintenance intervals Failure to use recommended fuel, lubricants and
coolant/antifreeze
2. Remove the connection (3). Loosen the locknut (1). 3. Remove the sensor (2). 4. Use a soft, dry cloth in order to clean any debris from the sensor (2). Note: Do not use a wire brush in order to clean the sensor. Do not use abrasive material in order to clean the sensor. 5. Install Tooling (A). Use Tooling (A) in order to rotate the engine. Rotate the engine in order to align a tooth on the ring gear with the center of the tapped hole. 6. By hand, carefully install the sensor (2) until light contact is made with the ring gear. Note: Do not tighten the sensor.
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Speed Sensor - Clean/Inspect (Engine Speed Sensor and Overspeed Sensor)

When the engine is cranked, small metal particles are produced. These particles will contaminate the magnetic end of the crankshaft position sensor and the overspeed sensor. Contamination will distort the signals that are produced by the sensors. The sensors should be regularly cleaned and adjusted in order to ensure a good signal.
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69 Maintenance Section Starting Motor - Inspect
4. Use a soft, dry cloth in order to clean any debris from the sensor (2). Note: Do not use a wire brush in order to clean the sensor. Do not use abrasive material in order to clean the sensor. 5. Install Tooling (A). Use Tooling (A) in order to rotate the engine. Rotate the engine in order to align a tooth on the ring gear with the center of the tapped hole. 6. By hand, carefully install the sensor (2) until light contact is made with the ring gear.
Illustration 67
g01237854
Note: Do not tighten the sensor.
7. Unscrew the sensor (2) by one complete turn in order to obtain a clearance (X) of 1 mm (0.04 inch). 8. Tighten the locknut (1). Do not allow the sensor (2) to rotate. Connect the connection (3). 9. Remove Tooling (A). 10. Restore the electrical supply to the engine.
Overspeed Sensor
The overspeed sensor is located in the left hand side of the ywheel housing. 1. Isolate the electrical supply to the engine.
Illustration 69
g01237854
7. Unscrew the sensor (2) by one complete turn in order to obtain a clearance (X) of 0.5 to 0.8 mm (0.02 to 0.03 inch). 8. Tighten the locknut (1). Do not allow the sensor (2) to rotate. Connect the connection (3). 9. Remove Tooling (A). 10. Restore the electrical supply to the engine.
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Starting Motor - Inspect

If a starting motor fails, the engine may not start in an emergency situation. A scheduled inspection of the starting motors is recommended.
g01237853
2. Remove the connection (3). Loosen the locknut (1). 3. Remove the sensor (2).
Note: Problems with the electric starting motor can be caused by the following conditions: malfunction of the solenoid and malfunction of the electric starting system. Inspect the electrical system for the following conditions:
70 Maintenance Section Turbocharger - Inspect
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Loose connections Corrosion Wires that are worn or frayed Cleanliness

Make repairs, if necessary. The starting motor pinion and the ywheel ring gear must be in good condition in order for the engine to start properly. The engine will not start if the starting motor pinion does not engage the ywheel ring gear. The teeth of the starting motor pinion and the ywheel ring gear can be damaged because of irregular engagement. Inspect the starting motors for proper operation. Listen for grinding when the engine is started. Inspect the teeth of the starting motor pinions and the ywheel ring gear. Look for patterns of wear on the teeth. Look for teeth that are broken or chipped. If damaged teeth are found, the starting motor pinions and the ywheel ring gear must be replaced. Refer to the Operation Manual TSL4165 for information on removing the starting motors and installing the starting motors.
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NOTICE Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems. Loss of engine lubricant can result in serious engine damage. Minor leakage of a turbocharger housing under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occurred. When a turbocharger bearing failure is accompanied by a signicant engine performance loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until the turbocharger is repaired or replaced. An inspection of the turbochargers can minimize unscheduled downtime. Also, the chance for potential damage to other engine parts is reduced. Note: Turbocharger components require clearances that are precise. The turbocharger cartridge must be balanced due to high rpm. The following conditions can cause a turbocharger to be out-of-balance:
The buildup of deposits Chipping and/or aking of deposits

If the turbocharger must be removed for inspection, use caution. Do not break deposits from the turbine wheel. Do not attempt to clean the turbine wheel. For options regarding removal, installation, repair and replacement, refer to the Service Manual, or consult a Perkins distributor. 1. Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger. Visually inspect the piping for the presence of oil. 2. Turn the compressor wheel and the turbine wheel by hand. The assembly should turn freely. Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing. There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing. If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing, the turbocharger should be reconditioned. 3. Check the compressor wheel for cleanliness. If only the inlet side of the wheel is dirty, dirt and/or moisture is passing through the air ltering system. If oil is found only on the back side of the wheel, there is a possibility of a failed turbocharger oil seal.
Turbocharger - Inspect
Periodic inspection and cleaning is recommended for the turbochargers. Fouling of the turbine wheels can contribute to loss of engine power and overall loss of engine efciency. If a turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to a turbocharger compressor wheel could allow parts from the compressor wheel to enter an engine cylinder. This can cause additional damage to the pistons, the valves, and the cylinder head.
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71 Maintenance Section Walk-Around Inspection
The presence of oil may be the result of extended engine operation at no load. The presence of oil may also result from restriction of the inlet air (plugged air lters). This causes oil to leak past the seal for the turbocharger compressor. Note: Deposits of ash and silicone can accumulate on the turbine wheel. Turbine wheel will become unbalanced when the deposits ake off. The turbocharger cartridge must be replaced when the turbine wheel becomes unbalanced. However, remove deposits from the housing. Removing deposits from the housing will prevent wear on the blades of the new turbine wheel. 4. Inspect the turbine wheel and the housing for deposits of ash and silicone. If deposits of 1.6 mm (0.06 inch) thickness are found or if the turbine is in contact with the housing, the turbocharger must be disassembled and cleaned. Removal of the deposits can be difcult. 5. Inspect the bore of the turbine housing for corrosion and deposits. 6. Clean the turbocharger compressor housing with standard shop solvents and a soft bristle brush. 7. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing.
i02415322
NOTICE For any type of leak (coolant, lube, or fuel) clean up the uid. If leaking is observed, nd the source and correct the leak. If leaking is suspected, check the uid levels more often than recommended until the leak is found or xed, or until the suspicion of a leak is proved to be unwarranted. NOTICE Accumulated grease and/or oil on an engine is a re hazard. Remove the accumulated grease and oil. Refer to Operation and Maintenance Manual, Engine Clean for more information.
Ensure that the cooling system hoses are correctly

clamped and that the cooling system hoses are tight. Check for leaks. Check the condition of all pipes.
Inspect the water pumps for coolant leaks.

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 the parts contract. Excessive coolant leakage may indicate the need to replace a water pump. Refer to Operation and Maintenance Manual, Water Pump - Inspect for more information. If necessary, consult your Perkins dealer or your Perkins distributor.
Walk-Around Inspection
A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided. For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections and trash buildup. Make repairs, as needed:
Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil pan, the oil lters and the rocker cover. elbows for cracks and for loose clamps. Ensure that hoses and tubes are not contacting other hoses, tubes, wiring harnesses, etc. clear.
Inspect the piping for the air intake system and the
Ensure that the areas around the rotating parts are Inspect the alternator belt and fan drive belts for
cracks, breaks or other damage.
The guards must be in the correct place. Repair damaged guards or replace missing guards. Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination.
Inspect the wiring harness for damage.

Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is 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.
72 Maintenance Section Water Pump - Inspect
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Water Pump - Inspect

A failed water pump may cause severe engine overheating problems that could result in the following conditions:
Cracks in the cylinder head A piston seizure Other potential damage to the engine
Note: The water pump seal is lubricated by the coolant in the cooling system. A normal condition is that a small amount of leakage to occur as the engine cools down and parts contract. Visually inspect the water pumps for leaks. The water pumps are not serviceable items. Replace a leaking water pump. Refer to Disassembly and Assembly for more information.
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73 Warranty Section Warranty Information
Warranty Section Warranty Information

i01903596
Emissions Warranty Information

This engine may be certied to comply with exhaust emission standards and gaseous emission standards that are prescribed by the law at the time of manufacture, and this engine may be covered by an Emissions Warranty. Consult your authorized Perkins dealer or your authorized Perkins distributor in order to determine if your engine is emissions certied and if your engine is subject to an Emissions Warranty.
74 Index Section
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Index
A Actuator Control Linkage - Lubricate ..................... After Stopping Engine............................................ Aftercooler Core - Clean/Test ................................ Aftercooler Core - Inspect...................................... Alternator - Inspect ................................................ Alternator Pulley - Check....................................... B Battery - Replace................................................... 43 Battery Electrolyte Level - Check .......................... 43 Battery or Battery Cable - Disconnect ................... 44 Before Starting Engine .................................... 10, 23 Belts - Inspect/Adjust/Replace (Alternator Belt) .... 46 Adjustment ......................................................... 46 Inspection........................................................... 46 Replacement...................................................... 46 Belts - Inspect/Adjust/Replace (Fan Drive Belts)... 44 Adjustment ......................................................... 45 Inspection........................................................... 44 Replacement...................................................... 45 Burn Prevention....................................................... 7 Batteries............................................................... 7 Coolant................................................................. 7 Oils....................................................................... 7 C Cold Weather Starting ........................................... 24 Cooling System Coolant - Change (Inhibitor) ........ 49 Drain .................................................................. 50 Fill ...................................................................... 51 Flush .................................................................. 51 Cooling System Coolant (ELC) - Change.............. 47 Drain .................................................................. 47 Fill ...................................................................... 49 Flush .................................................................. 48 Cooling System Coolant Level - Check ................. 52 Crushing Prevention and Cutting Prevention .......... 9 D Driven Equipment - Check..................................... 52 E Electrical System .................................................... 11 Emergency Stopping ............................................. 26 Emissions Warranty Information............................ 73 Engine - Clean....................................................... 53 Engine Air Cleaner Element - Replace.................. 53 41 26 41 42 42 42 Engine Air Cleaner Service Indicator - Inspect...... 54 Service Indicator Check ..................................... 54 Service Indicator Reset...................................... 54 Engine Crankcase Breather - Clean...................... 54 Engine Description ................................................ 15 Engine Cooling and Lubrication ......................... 16 Engine Specications......................................... 15 Engine Electronics.................................................. 11 System Description ............................................. 11 Engine Lifting......................................................... 19 Engine Mounts - Inspect........................................ 55 Engine Oil and Filter - Change .............................. 57 Drain the Engine Lubricating Oil ........................ 58 Fill the Oil Pan.................................................... 58 Replace the Oil Filter ......................................... 58 Engine Oil Filter (Auxiliary) - Change .................... 55 Change the Filter with the Engine in Operation.. 55 Engine Oil Level - Check ....................................... 56 Engine Oil Pump - Inspect..................................... 56 Engine Oil Sample - Obtain ................................... 57 Initiating an Oil analysis Program ...................... 57 Obtain the Sample and the Analysis.................. 57 Engine Operation................................................... 25 Engine Protective Devices - Check ....................... 59 Visual Inspection................................................ 59 Engine Starting ................................................ 10, 23 Engine Stopping .............................................. 10, 26 Engine Storage...................................................... 19 Level A ........................................................... 19 Level B ........................................................... 19 Level C .......................................................... 19 Engine Valve Lash - Inspect/Adjust (Valves and Valve Bridges) ............................................................... 59 F Fan Drive Pulley - Check....................................... 59 Features and Controls ........................................... 20 Fire Prevention and Explosion Prevention .............. 7 Fire Extinguisher .................................................. 9 Lines, Tubes and Hoses ...................................... 9 Fluid Recommendations........................................ 27 Cooling System Specications........................... 35 ELC Cooling System Maintenance .................... 37 Engine Oil .......................................................... 28 Fuel Specications............................................. 31 General Lubricant Information ........................... 27 Foreword ................................................................. 4 California Proposition 65 Warning ....................... 4 Literature Information........................................... 4 Maintenance ........................................................ 4 Maintenance Intervals.......................................... 4 Operation ............................................................. 4 Overhaul .............................................................. 4 Safety................................................................... 4 Fuel Conservation Practices.................................. 25 Fuel Injector - Inspect/Adjust ................................. 60
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75 Index Section
Fuel System - Prime .............................................. Fuel System Filter - Replace ................................. Fuel Filter with Water Separator ........................ Fuel System Primary Filter/Water Separator Drain .................................................................... Fuel Tank Water and Sediment - Drain ................. Drain the Water and the Sediment..................... Fuel Storage Tanks ............................................ Fuel Tank ........................................................... Fuel Transfer Pump (Lift Pump) - Inspect ............. Replacement of the Lift Pump............................ G
60 61 61 62 62 63 63 63 63 63
P Plate Locations and Film Locations....................... Engine Identication........................................... Serial Number Plate........................................... Product Identication Information .......................... Product Information Section .................................. R Radiator - Clean .................................................... Rell Capacities..................................................... Cooling System.................................................. Fuel System ....................................................... Lubrication System ............................................ S Safety Messages ..................................................... 5 (1) Universal Warning .......................................... 5 (2) Hot Coolant..................................................... 5 Safety Section ......................................................... 5 Sensors and Electrical Components ..................... 20 Boost Pressure Sensors .................................... 21 Coolant Temperature Switches .......................... 21 Engine Oil Pressure Switch ............................... 22 Overspeed Sensor ............................................. 22 Sensor Locations ............................................... 20 Speed Sensor .................................................... 21 Severe Service Application - Check ...................... 67 Environmental Factors ....................................... 68 Incorrect Maintenance Procedures .................... 68 Incorrect Operating Procedures......................... 68 Speed Sensor - Clean/Inspect (Engine Speed Sensor and Overspeed Sensor)....................................... 68 Engine Speed Sensor ........................................ 68 Overspeed Sensor ............................................. 69 Starting Motor - Inspect ......................................... 69 Starting the Engine ................................................ 23 Normal Engine Starting Procedure .................... 23 Stopping the Engine .............................................. 26 T Table of Contents..................................................... 3 Turbocharger - Inspect .......................................... 70 W Walk-Around Inspection ........................................ Warranty Information ............................................. Warranty Section ................................................... Water Pump - Inspect ............................................ Welding on Engines with Electronic Controls ........ 71 73 73 72 12 67 27 27 27 27 17 17 18 17 12
General Hazard Information .................................... 5 Containing Fluid Spillage ..................................... 6 Fluid Penetration.................................................. 6 Pressure Air and Water........................................ 6 General Information............................................... 12 Governor Actuator - Check.................................... 64 H Hoses and Clamps - Inspect/Replace ................... 64 Replace the Hoses and the Clamps .................. 64 I Important Safety Information ................................... 2 L Lifting and Storage ................................................ 19 M Maintenance Interval Schedule ............................. 40 Maintenance Section ............................................. 27 Model View Illustrations......................................... 13 4012-46A ........................................................... 13 Model Views .......................................................... 13 Monitoring System................................................. 20 Mounting and Dismounting...................................... 9 O Operation Section.................................................. Overhaul (Major).................................................... Major Overhaul Information ............................... Scheduling a Major Overhaul............................. Overhaul (Top End) ............................................... Scheduling a Top End Overhaul ........................ Top End Overhaul Information ........................... 19 65 65 65 66 66 66
76 Index Section
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Product and Dealer Information

Note: For product identication plate locations, see the section Product Identication Information in the Operation and Maintenance Manual. Delivery Date:
Product Information
Model: Product Identication Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:
Dealer Information
Name: Address: Branch:
Dealer Contact Sales: Parts: Service:
Phone Number
Hours
2011 Perkins Engines Company Limited All Rights Reserved
Printed in U.K.

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SEBU8191-01 November 2011

Operation and Maintenance Manual

Important Safety Information

Product Information Section

California Proposition 65 Warning

5 Safety Section Safety Messages

(2) Hot Coolant

(1) Universal Warning

General Hazard Information

6 Safety Section General Hazard Information

Pressure Air and Water

Containing Fluid Spillage

Only use the tools that are suitable for collecting

uids and equipment that is suitable for collecting uids.

7 Safety Section Burn Prevention

Only use the tools that are suitable for containing

uids and equipment that is suitable for containing uids.

Obey all local regulations for the disposal of liquids.

Fire Prevention and Explosion Prevention

8 Safety Section Fire Prevention and Explosion Prevention

9 Safety Section Crushing Prevention and Cutting Prevention

Crushing Prevention and Cutting Prevention

Lines, Tubes and Hoses

Mounting and Dismounting

10 Safety Section Before Starting Engine

Before Starting Engine

11 Safety Section Electrical System

Setpoint adjusters (if equipped) Sensors Wiring Harness

Control unit Actuator

12 Product Information Section General Information

Product Information Section General Information

Welding on Engines with Electronic Controls

13 Product Information Section Model Views

Model View Illustrations

14 Product Information Section Model Views

15 Product Information Section Model Views

16 Product Information Section Model Views

Engine Cooling and Lubrication

Gear-driven water pumps Water temperature regulators which regulate the

Gear-driven oil pump (gear type) Oil coolers

17 Product Information Section Product Identication Information

Product Identication Information

Plate Locations and Film Locations

18 Product Information Section Product Identication Information

Serial Number Plate

Illustration 13 Serial number plate

The location of the serial number plate for vee-form engines

The engine serial number plate contains the following information:

19 Operation Section Lifting and Storage

Operation Section Lifting and Storage

20 Operation Section Features and Controls

Features and Controls

Sensors and Electrical Components

21 Operation Section Features and Controls

Coolant Temperature Switches

Illustration 18 Coolant temperature switch

Illustration 20 Speed sensor

Boost Pressure Sensors

Failure of the Speed Sensor

Cetane number_________________________________50 Viscosity_ 1.5 to 5.0 cSt at 40 C (104 F) Carbon residue______________________________0.20%

Cetane number_________________________________45 Viscosity_ 1.5 to 5.5 cSt at 40 C (104 F) Carbon residue______________________________0.20%