Operation and

Maintenance

Manual

1204E-E44TA and  1204E-E44TTA

Industrial Engines

MK (Engine)

ML (Engine)

This document is printed from SPI². Not for RESALE

Important Safety Information

Most  accidents    tha t involve  produc  t  op eration,  ma intena nc e and   repair   are  caus  ed  by  failure  to

ob serve  basic   safety   rules  or  precautions  .  An accident    can   often  be  avoided   by  recog nizing  pote ntially

ha za rdous  situations   before   an  accident    oc curs . A person    mus t be  alert   to pote ntial  ha za rds.  This

person   should   also  ha ve  the  ne cessary   training,  skills  and   tools  to perform   the se  func tions 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.

Sa fety precautions     and  warning s  are   provided   in this  ma nua l and   on  the  produc t.  If the se  ha za rd

warning s  are  not  he eded,   bod ily injury  or death   could   oc cur to  you  or to  othe r persons  .

The  ha za rds are   identified   by  the  “Safety  Alert  Symb ol”  and  followed  by  a  “Signa l  Word” suc h  as

“DANGER”, “WARNING”  or “CAUTION”.  The Sa fety  Alert  “WARNING” label  is  shown   below.

The  me aning  of  this safety   alert   symb ol is  as  follows:

Attention! Become Alert! Your Safety is  Involved.

The  me ssage   tha t appears     und er the   warning  explains    the  ha za rd and   can  be   either  written  or

pictorially   presente  d.

Op erations  tha t  ma y caus e  produc  t dama  ge  are  identified   by  “NOTICE” labels   on  the  produc  t and   in

this  pub lication.

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  informa tion, specifications   ,  and  illustrations   in  this  pub lication  are   on the  basis    of informa tion tha t

was  available    at  the  time  tha t the  pub lication   was  written.   The  specifications   , torque  s,  pressure  s,

me asure me nts , adjustme  nts , illustrations ,  and  othe r  items  can  cha  ng e at  any  time.  These  cha ng es  can

affect   the  service   tha t is given   to the  produc  t.  Ob tain the  comp  lete  and  mos t current   informa tion before

you  start any   job. Pe  rkins  dealers   or   Pe rkins  distributors     ha ve  the  mos t current   informa tion  available.

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

This document is printed from SPI². Not for RESALE

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Table of Contents

Table of Contents

Maintenance Interval Schedule ............................  80

Warranty Section

Foreword ................................................................. 4

Warranty Information ........................................... 113

Safety Section

Reference Information Section

Safety Messages ....................................................  5

General Hazard Information ...................................  7

Burn Prevention .................................................... 10

Fire Prevention and Explosion Prevention ............. 11

Crushing Prevention and Cutting Prevention ........ 13

Mounting and Dismounting ................................... 13

High Pressure Fuel Lines .....................................  13

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

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

Engine Stopping ...................................................  16

Electrical System ..................................................  16

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

Reference Materials ............................................. 117

Index Section

Index .................................................................... 118

Product Information Section

Model Views .........................................................  18

Product Identification Information  ........................  27

Operation Section

Lifting and Storage ................................................ 30

Gauges and Indicators .......................................... 34

Features and Controls ..........................................  36

Engine Diagnostics ............................................... 46

Engine Starting .....................................................  52

Engine Operation .................................................. 55

Engine Stopping ...................................................  57

Cold Weather Operation ....................................... 59

Maintenance Section

Refill Capacities ....................................................  63

Maintenance Recommendations ..........................  78

This document is printed from SPI². Not for RESALE

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SEBU8605-01

Foreword

Foreword

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

specified in the Maintenance Interval Schedule may

be necessary.

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.

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.

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.

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.

Safety

Your authorized Perkins dealer  or your Perkins

distributor can assist  you in adjusting  your

maintenance schedule to meet the needs of  your

operating environment.

This safety section lists basic safety  precautions.

In addition, this  section identifies hazardous,

warning situations. Read and understand the basic

precautions listed in  the safety section before

operating or 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

efficiently 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.

This document is printed from SPI². Not for RESALE

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Safety Section

Safety Messages

Safety Section

The Universal Warning label (1) is  located in two

positions. The warning labels are located on the rear

right side of the valve mechanism cover and located

on the top for the NOx reduction system (NRS).

i04229669

Safety Messages

There may be several specific warning signs on your

engine. The exact location and a description of the

warning signs are reviewed in this section. Please

become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean

the warning signs or replace the  warning signs if

the words cannot be read or if the illustrations are

not visible. Use a cloth, water, and  soap to clean

the warning signs. Do not use solvents, gasoline, or

other harsh chemicals. Solvents, gasoline, or harsh

chemicals could loosen the adhesive that secures the

warning signs. The warning signs that are loosened

could drop off the engine.

Replace any warning sign  that is damaged or

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 distributor can

provide new warning signs.

(1) Universal Warning

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.

g01154807

Illustration 1

Typical example

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SEBU8605-01

Safety Section

Safety Messages

g02406137

Illustration 2

(1) Universal Warning

(2) Hand (High Pressure)

Contact with  high pressure fuel  may cause fluid

penetration and  burn hazards. High pressure  fu-

el spray  may cause  a fire  hazard. Failure to  fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

g02382677

Illustration 3

Typical example

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Safety Section

General Hazard Information

g01154809

i03566024

Illustration 5

Typical example

General Hazard Information

g02406178

Illustration 4

(2) Hand (High Pressure)

The warning label for the  Hand (High Pressure)

(2) is a wrap around label  that is installed on the

high-pressure fuel line.

Ether Warning

The ether warning label will be installed on the  air

cleaner or close to the air cleaner. The location will

depend on the application.

g00104545

Illustration 6

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

warning tag to the start  switch or to the controls

before the engine is serviced or before the engine is

repaired. Attach the warning tags to the engine and to

each operator control station. When it is appropriate,

disconnect the starting controls.

Do not use aerosol types of starting aids such as

ether. Such use could  result in an explosion and

personal injury.

Do not allow unauthorized personnel on the engine,

or around the engine when  the engine is being

serviced.

•  Tampering with the engine installation or tampering

with the OEM supplied wiring can be dangerous.

Personal injury, death and/or engine damage could

result.

•  Vent the engine exhaust to the outside when the

engine is operated in an enclosed area.

This document is printed from SPI². Not for RESALE

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SEBU8605-01

Safety Section

General Hazard Information

•  If the engine is not running,  do not release the

secondary brake or the parking brake  systems

unless the vehicle is blocked or unless the vehicle

is restrained.

•  For initial start-up of a new engine or for starting an

engine that has been serviced, make provisions to

stop the engine if an overspeed occurs. This may

be accomplished by shutting off the fuel  supply

and/or the air supply to the engine.

•  Wear a hard hat, protective glasses,  and other

protective equipment, as required.

•  Start the engine from the operator's station (cab).

Never short across the starting motor terminals or

the batteries. This could bypass the engine neutral

start system and/or the electrical system could be

damaged.

•  When work is performed around an engine that is

operating, wear protective devices for ears in order

to help prevent damage to hearing.

•  Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

Engine exhaust contains products of combustion

which may be harmful to your health. Always start the

engine and operate the engine in a well ventilated

area. If the engine is in an enclosed area, vent the

engine exhaust to the outside.

•  Ensure that all protective guards and all covers are

secured in place on the engine.

•  Never put maintenance fluids into glass containers.

Cautiously remove the following  parts. To help

prevent spraying or splashing of pressurized fluids,

hold a rag over the part that is being removed.

Glass containers can break.

•  Use all cleaning solutions with care.

•  Report all necessary repairs.

•  Filler caps

•  Grease fittings

•  Pressure taps

•  Breathers

Unless other instructions are provided, perform the

maintenance under the following conditions:

•  The engine is stopped. Ensure that the engine can

not be started.

•  Drain plugs

•  The protective locks or the  controls are in the

applied position.

Use caution when  cover plates are removed.

Gradually loosen, but do not remove the  last two

bolts or nuts that are located at  opposite ends of

the cover plate or the device. Before removing the

last two bolts or nuts, pry the cover loose in order to

relieve any spring pressure or other pressure.

•  Engage the secondary brakes or parking brakes.

•  Block the vehicle or restrain the  vehicle before

maintenance or repairs are performed.

•  Disconnect the batteries when  maintenance

is performed or when  the electrical system is

serviced. Disconnect the battery ground leads.

Tape the leads in order to help prevent sparks.

•  Disconnect the connector for the unit injector that

is located on the valve cover base. This will help

prevent personal injury from the high voltage to the

unit injectors. Do not come in contact with the unit

injector terminals while the engine is operating.

•  Do not attempt any repairs or any adjustments to

the engine while the engine is operating.

g00702020

•  Do not attempt any repairs that are not understood.

Use the proper tools. Replace any equipment that

is damaged or repair the equipment.

Illustration 7

•  Wear a hard hat, protective glasses,  and other

protective equipment, as required.

•  When work is performed around an engine that is

operating, wear protective devices for ears in order

to help prevent damage to hearing.

This document is printed from SPI². Not for RESALE

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Safety Section

General Hazard Information

•  Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

•  Ensure that all protective guards and all covers are

secured in place on the engine.

•  Never put maintenance fluids into glass containers.

Glass containers can break.

•  Use all cleaning solutions with care.

•  Report all necessary repairs.

Unless other instructions are provided, perform

the maintenance under the following conditions:

g00687600

Illustration 8

•  The engine is stopped. Ensure that  the engine

cannot be started.

Always use a board or cardboard when you check

for a leak. Leaking fluid that is under pressure can

penetrate body tissue. Fluid penetration can cause

serious injury and possible death. A pin hole leak can

cause severe injury. If fluid is injected into your skin,

you must get treatment immediately. Seek treatment

from a doctor that is familiar with this type of injury.

•  Disconnect the batteries when  maintenance

is performed or when  the electrical system is

serviced. Disconnect the battery ground leads.

Tape the leads in order to help prevent sparks.

•  Do not attempt any repairs that are not understood.

Use the proper tools. Replace any equipment that

is damaged or repair the equipment.

Containing Fluid Spillage

NOTICE

Pressurized Air and Water

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Pressurized air and/or water  can cause debris

and/or hot water to be blown out. This could result in

personal injury.

When pressurized air and/or pressurized water is

used for cleaning, wear protective clothing, protective

shoes, and eye protection. Eye protection includes

goggles or a protective face shield.

Dispose of all fluids according to local regulations and

mandates.

Asbestos Information

The maximum air pressure for cleaning purposes

must be below 205 kPa  (30 psi). The maximum

water pressure for cleaning purposes must be below

275 kPa (40 psi).

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long

after the engine has been stopped. The pressure can

cause hydraulic fluid 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.

g00702022

Illustration 9

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SEBU8605-01

Safety Section

Burn Prevention

Dispose of Waste Properly

Perkins replacement parts that are shipped  from

Perkins are asbestos free. Perkins recommends

the use of only genuine Perkins replacement parts.

Use the following guidelines when you handle any

replacement parts that contain asbestos or when you

handle asbestos debris.

Use caution. Avoid inhaling  dust that might be

generated when you handle components that contain

asbestos fibers. Inhaling this dust can be hazardous

to your health. The components that may contain

asbestos fibers are brake pads, brake bands, lining

material, clutch plates, and  some gaskets. The

asbestos that is used in these components is usually

bound in a resin or sealed  in some way. Normal

handling is not hazardous unless airborne dust that

contains asbestos is generated.

g00706404

Illustration 10

If dust that may contain asbestos is present, there

are several guidelines that should be followed:

Improperly disposing of waste can  threaten the

environment. Potentially harmful fluids should be

disposed of according to local regulations.

•  Never use compressed air for cleaning.

Always use leakproof containers when you  drain

fluids. Do not pour waste onto the ground, down a

drain, or into any source of water.

•  Avoid brushing materials that contain asbestos.

•  Avoid grinding materials that contain asbestos.

•  Use a wet method in order to clean up asbestos

materials.

i04224009

Burn Prevention

•  A vacuum cleaner that is equipped  with a high

efficiency particulate air filter (HEPA) can also be

used.

Do not touch  any part of an operating  engine

system. The engine, the exhaust, and the  engine

aftertreatment system surface temperatures can

reach temperatures of  approximately 600° C

(1112 ° F) under normal operating conditions.

•  Use exhaust ventilation on permanent machining

jobs.

•  Wear an approved respirator if there is no other

way to control the dust.

Allow the engine  system to cool  before any

maintenance is performed.

•  Comply with applicable rules  and regulations

for the work place.  In the United States, use

Occupational Safety and Health Administration

(OSHA) requirements. These OSHA requirements

can be found in “29 CFR 1910.1001”.

Relieve all pressure  in the following systems,

hydraulic system, lubrication system, fuel system,

and the coolant system before the related items are

disconnected.

•  Obey environmental regulations for the disposal

of asbestos.

Contact with  high pressure fuel  may cause fluid

penetration and  burn hazards. High pressure  fu-

el spray  may cause  a fire  hazard. Failure to  fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

•  Stay away from areas that might have asbestos

particles in the air.

After the engine has stopped, you must wait for 10

minutes in order to allow  the fuel pressure to be

purged from the high-pressure fuel lines before any

service or repair is performed on the engine fuel lines.

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Safety Section

Fire Prevention and Explosion Prevention

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,  fittings, or

related items are disconnected.

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.

Induction System

i03652933

Fire Prevention and Explosion

Prevention

Sulfuric Acid Burn Hazard may cause serious per-

sonal injury or death.

The  exhaust  gas   cooler  may  contain  a  small

amount of sulfuric acid.  The use of fuel with sul-

fur levels  greater than 15  ppm may increase  the

amount of sulfuric acid formed. The  sulfuric acid

may  spill from  the cooler  during  service of  the

engine. The sulfuric  acid will burn the eyes, skin

and clothing on contact.  Always wear the appro-

priate personal  protective  equipment (PPE)  that

is noted  on a material  safety data  sheet (MSDS)

for sulfuric acid. Always follow  the directions for

first aid  that are noted  on a material  safety data

sheet (MSDS) for sulfuric acid.

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.

g00704000

Illustration 11

All fuels, most lubricants, and some coolant mixtures

are flammable.

Any contact with hot coolant or with steam can cause

severe burns. Allow cooling system components to

cool before the cooling system is drained.

Flammable fluids that are leaking or spilled onto hot

surfaces or onto electrical components can cause

a fire. Fire may cause personal injury and property

damage.

Check that the coolant level after  the engine has

stopped and the engine has been allowed to cool.

After the emergency stop button is operated ensure

that you allow 15 minutes, before the engine covers

are removed.

Ensure that the filler cap is cool before removing the

filler cap. The filler cap must be cool enough to touch

with a bare hand. Remove the filler  cap slowly in

order to relieve pressure.

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.

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contact

the skin, the eyes, or the mouth.

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.

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.

Remove all flammable combustible materials  or

conductive materials such as fuel, oil, and debris from

the engine. Do not allow any flammable combustible

materials or conductive materials to accumulate on

the engine.

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SEBU8605-01

Safety Section

Fire Prevention and Explosion Prevention

Store fuels and  lubricants in correctly marked

containers away from unauthorized persons. Store

oily rags and any flammable materials in protective

containers. Do not smoke in areas that are used for

storing flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaust

components from oil or fuel spray in case of a line,

a tube, or a seal failure. Exhaust  shields must be

installed correctly.

Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines or tanks that contain

flammable fluid. Clean any  such lines or tanks

thoroughly with a nonflammable  solvent prior to

welding or flame cutting.

Wiring must be kept in good condition. 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.

g00704059

Illustration 12

Use caution when you are refueling an engine. Do

not smoke while you are refueling an engine. Do not

refuel an engine near open flames or sparks. Always

stop the engine before refueling.

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 fire. Secure

connections, recommended wiring, and correctly

maintained battery cables will help to prevent arcing

or sparking.

Contact with  high pressure fuel  may cause fluid

penetration and  burn hazards. High pressure  fu-

el spray  may cause  a fire  hazard. Failure to  fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

After the engine has stopped, you must wait for 10

minutes in order to allow the  fuel pressure to be

purged from the high pressure fuel lines before any

service or repair is performed on the engine fuel lines.

g00704135

Illustration 13

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.

Gases from a battery can explode. Keep any open

flames 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.

Oil filters and fuel filters must be correctly installed.

The filter housings must be tightened to the correct

torque. Refer to the Disassembly  and Assembly

manual for more information.

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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 specific

instructions.

i02143194

Crushing Prevention and

Cutting Prevention

Do not charge a frozen battery. This may cause an

explosion.

Support the component correctly when work beneath

the component is performed.

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.

Unless other maintenance instructions are provided,

never attempt adjustments while  the engine is

running.

Fire Extinguisher

Stay clear of all rotating  parts and of all moving

parts. Leave the guards in place until maintenance

is performed. After the maintenance is performed,

reinstall the guards.

Make sure that a fire extinguisher is available.  Be

familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and  service the fire

extinguisher regularly. Obey the recommendations

on the instruction plate.

Keep objects away from moving fan blades. The fan

blades will throw objects or cut objects.

Lines, Tubes and Hoses

When objects are struck, wear protective glasses in

order to avoid injury to the eyes.

Do not bend high pressure lines. Do not strike high

pressure lines. Do not  install any lines that are

damaged.

Chips or other debris may fly off objects when objects

are struck. Before objects are struck, ensure that no

one will be injured by flying debris.

Leaks can cause fires. Consult your Perkins dealer

or your Perkins distributor for replacement parts.

i04016709

Replace the parts if any of the following conditions

are present:

Mounting and Dismounting

•  High pressure fuel line or lines are removed.

•  End fittings are damaged or leaking.

•  Outer coverings are chafed or cut.

•  Wires are exposed.

Do not  climb on the  engine or the  engine

aftertreatment. The engine and aftertreatment have

not been designed with mounting or  dismounting

locations.

Refer to the OEM for the location of foot and hand

holds for your specific application.

•  Outer coverings are ballooning.

•  Flexible part of the hoses are kinked.

•  Outer covers have embedded armoring.

•  End fittings are displaced.

i03814031

High Pressure Fuel Lines

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.

Contact with  high pressure fuel  may cause fluid

penetration and  burn hazards. High pressure  fu-

el spray  may cause  a fire  hazard. Failure to  fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

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14

SEBU8605-01

Safety Section

High Pressure Fuel Lines

g02067853

Illustration 14

(1) High-pressure line

(2) High-pressure line

(3) High-pressure line

(4) High-pressure line

(5) High-pressure fuel manifold (rail)

(6) High-pressure line

(7) Fuel transfer line that is high pressure

The high-pressure fuel lines are the fuel lines that

are between the high-pressure fuel pump and the

high-pressure fuel manifold and the fuel lines that are

between the fuel manifold and cylinder head. These

fuel lines are different from fuel lines on other  fuel

systems.

Do not loosen the high-pressure fuel lines in order

to remove air from the fuel system. This procedure

is not required.

Visually inspect the high-pressure fuel lines before

the engine is started. This inspection should be each

day.

These differences are because of the following items:

If you inspect the engine in operation, always use

the proper inspection procedure in order to  avoid

a fluid penetration hazard. Refer to Operation and

Maintenance Manual, “General hazard Information”.

•  The high-pressure fuel lines are constantly charged

with high pressure.

•  The internal pressures of the high-pressure fuel

lines are higher than other types of fuel system.

•  Inspect the high-pressure fuel lines for damage,

deformation, a nick, a cut, a crease, or a dent.

•  The high-pressure fuel lines are formed to shape

and then strengthened by a special process.

•  Do not operate the engine with a fuel leak. If there

is a leak, do not tighten the connection  in order

to stop the leak. The  connection must only be

tightened to the recommended torque. Refer to

Disassembly and Assembly, “Fuel injection lines -

Remove and Fuel injection lines - Install”.

Do not step on the high-pressure fuel lines. Do not

deflect the high-pressure fuel lines. Do not bend or

strike the high-pressure fuel lines. Deformation or

damage of the high-pressure fuel lines may cause a

point of weakness and potential failure.

•  If the high-pressure fuel lines are torqued correctly,

and the high-pressure fuel lines are leaking the

high-pressure fuel lines must be replaced.

Do not check the high-pressure fuel lines with the

engine or the starting motor in operation. After the

engine has stopped wait 10 minutes in order to allow

the fuel pressure to be purged from the high-pressure

fuel lines. before any service or repair is performed.

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SEBU8605-01

15

Safety Section

Before Starting Engine

•  Ensure that all clips on the high-pressure fuel lines

are in place. Do not operate the engine with clips

that are damaged, missing, or loose.

i03996487

Engine Starting

•  Do not attach any other item to the high-pressure

fuel lines.

•  Loosened high-pressure fuel  lines must be

replaced. Also removed high-pressure fuel lines

must be replaced. Refer  to Disassembly and

Assembly manual, “ Fuel Injection Lines - Install”.

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.

i02813489

Before Starting Engine

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.

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.

Start the engine from the operators compartment or

from the engine start switch.

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.

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 that the correct procedure will help

to prevent major damage to the engine components.

Knowing that the proce, dure will also help to prevent

personal injury.

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.

To ensure that the jacket water heater (if equipped)

and/or the lube oil heater (if equipped) is  working

correctly, check the water temperature gauge. Also,

check the oil temperature gauge during the heater

operation.

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.

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.

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.

Note: The engine is equipped with a device for cold

starting. If the engine will be operated in very cold

conditions, then an extra cold starting aid may be

required. Normally, the engine will be equipped with

the correct type of starting  aid for your region of

operation.

See the  Service Manual for repairs  and for

adjustments.

These engines are equipped with a glow plug starting

aid in each individual cylinder that heats the intake air

in order to improve starting. Some Perkins engines

may have a cold starting system that is controlled by

the ECM that allows a controlled flow of ether into

the engine. The ECM will disconnect the glow plugs

before the ether is introduced. This system would

be installed at the factory.

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SEBU8605-01

Safety Section

Engine Stopping

i02234873

Grounding Practices

Engine Stopping

Stop the engine according  to the procedure in

the Operation and Maintenance Manual, “Engine

Stopping (Operation Section)” in order  to avoid

overheating of the engine and accelerated wear of

the engine components.

Use the Emergency Stop Button (if equipped) 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.

g02407417

To stop an electronically controlled engine, cut the

power to the engine and/or shutting off the air supply

to the engine.

Illustration 15

Typical example

(1) Ground to the battery

(2) Primary position for grounding

(3) Ground to the starting motor

(4) Ground to the engine block

i04231629

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 primary position for

grounding.

Check the electrical  wires daily for wires that

are loose or frayed.  Tighten all loose electrical

connections before the engine is started. Repair all

frayed electrical wires before the engine is started.

See the Operation and Maintenance  Manual for

specific starting instructions.

g02407418

Illustration 16

Typical example

(5) Ground to the battery

(6) Ground to the cylinder block

Correct grounding for the engine electrical system

is necessary for optimum  engine performance

and reliability. Incorrect grounding  will result in

uncontrolled electrical circuit paths and in unreliable

electrical circuit paths.

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SEBU8605-01

17

Safety Section

Engine Electronics

Uncontrolled electrical circuit paths can  result in

damage to the crankshaft bearing journal surfaces

and to aluminum components.

•  Derate

•  Shutdown

Engines that are installed without engine-to-frame

ground straps can  be damaged by electrical

discharge.

The following monitored engine operating conditions

have the ability to limit  engine speed and/or the

engine power:

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.

•  Engine Coolant Temperature

•  Engine Oil Pressure

•  Engine Speed

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.

•  Intake Manifold Air Temperature

•  Engine Intake Throttle Valve Fault

•  Wastegate Regulator

The power supply connections  and the ground

connections for the engine electronics should always

be from the isolator to the battery.

•  Supply Voltage to Sensors

•  Fuel Pressure in Manifold (Rail)

•  NOx Reduction System

i03642610

Engine Electronics

•  Engine Aftertreatment System

The Engine Monitoring package can vary for different

engine models and different engine applications.

However, the monitoring system and  the engine

monitoring control will be similar for all engines.

Tampering with the electronic system installation

or the OEM  wiring installation can be  dangerous

and could result in personal injury or death and/or

engine damage.

Note: Many of the engine control systems and display

modules that are available for Perkins Engines will

work in unison with the Engine Monitoring System.

Together, the two controls will provide the engine

monitoring function for the specific engine application.

Refer to Troubleshooting for more information on the

Engine Monitoring System.

Electrical Shock Hazard. The electronic unit injec-

tors use DC voltage. The ECM sends this voltage

to the  electronic  unit injectors.  Do not  come in

contact with  the harness connector for  the elec-

tronic unit injectors while the engine is operating.

Failure to  follow  this instruction  could result  in

personal injury or death.

This engine has a comprehensive, programmable

Engine Monitoring System. The Electronic Control

Module (ECM) has the ability to monitor the engine

operating conditions. If any of the engine parameters

extend outside an allowable range, the  ECM will

initiate an immediate action.

The following actions  are available for engine

monitoring control:

•  Warning

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SEBU8605-01

Product Information Section

Model Views

Product Information

Section

Model Views

i04231649

Model View Illustrations

The following model views show typical  features

of the engine  and the aftertreatment system.

Due to individual  applications, your engine, or

your aftertreatment may appear different from the

illustrations.

1204E-E44TTA

g02409511

Illustration 17

(1) Front lifting eye

(6) Electronic control module (ECM)

(11) Oil sampling valve

(2) Crankcase breather

(3) NOx Reduction system (NRS)

(4) Primary fuel filter

(7) Fuel priming pump

(8) Oil gauge (dipstick)

(9) Fuel strainer

(12) Oil filler

(13) High-pressure fuel pump

(5) Secondary fuel filter

(10) Oil filter

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SEBU8605-01

19

Product Information Section

Model Views

g02409512

Illustration 18

(14) Rear lifting eye

(18) Starting motor

(19) Oil drain plug

(20) Exhaust outlet

(21) Flywheel housing

(22) Flywheel

(23) NRS cooler

(15) High-pressure turbocharger

(16) Low-pressure turbocharger

(17) Back pressure valve

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SEBU8605-01

Product Information Section

Model Views

g02409862

Illustration 19

(24) Belt

(25) Air intake

(26) Coolant outlet connection

(27) Thermostat housing

(28) Water pump

(29) Coolant inlet connection

(30) Crankshaft pulley

(31) Belt tensioner

(32) Alternator

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SEBU8605-01

21

Product Information Section

Model Views

1204E-E44TA

g02407436

Illustration 20

(1) Front lifting eye

(5) Primary fuel filter

(9) Oil filter

(2) Crankcase breather

(3) NOx reduction system (NRS)

(4) Secondary fuel filter

(6) Fuel priming pump

(7) Fuel strainer

(8) Electronic control module (ECM)

(10) Oil sampling valve

(11) High-pressure fuel pump

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SEBU8605-01

Product Information Section

Model Views

g02407536

Illustration 21

(12) Rear lifting eye

(13) Oil gauge (dipstick)

(14) Turbocharger

(16) Oil drain valve

(17) Oil drain plug

(18) Back pressure valve

(19) Flywheel housing

(20) Flywheel

(21) Exhaust outlet

(22) NRS cooler

(15) Starting motor

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SEBU8605-01

23

Product Information Section

Model Views

g02407537

Illustration 22

(23) Oil filler

(24) Air intake

(25) Outlet connection for coolant

(26) Thermostat housing

(27) Water pump

(31) Alternator

(32) Belt

(28) Coolant intake connector

(29) Rear lifting eye

(30) Belt tensioner

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SEBU8605-01

Product Information Section

Model Views

Engine Aftertreatment System

g02483616

Illustration 23

Typical example

(1) Flexible exhaust pipe

(2) Inlet connection

(3) Clean emissions module

(4) Mounting cradle

(5) Outlet connection

•  Turbocharged charge cooled

i04340692

Engine Description

Engine Specifications

The front end of the engine is opposite the flywheel

end of the engine. The left and the right sides of the

engine are determined from the flywheel end. The

number 1 cylinder is the front cylinder.

Perkins has designed two versions of  the 1204E

industrial engine.

•  1204E-E44TA (MK)

•  1204E-E44TTA (ML)

The 1204E-E44TA (MK) engine is equipped with a

single turbocharger.

The 1204E-E44TTA (ML) engine is equipped with

series turbochargers. An engine that is  equipped

with series turbochargers have  a low-pressure

turbocharger and a high-pressure turbocharger.

The Perkins 1204E industrial  engines have the

following characteristics.

•  In-line four cylinder

•  Four stroke cycle

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SEBU8605-01

25

Product Information Section

Model Views

Electronic Engine Features

The engine operating conditions are  monitored.

The Electronic Control Module (ECM) controls the

response of the engine to these conditions and  to

the demands of the operator. These conditions and

operator demands determine the precise control of

fuel injection by the ECM. The  electronic engine

control system provides the following features:

•  Engine monitoring

•  Engine speed governing

•  Control of the injection pressure

•  Cold start strategy

•  Automatic air/fuel ratio control

•  Torque rise shaping

g01187485

Illustration 24

•  Injection timing control

(A) Exhaust valves

(B) Inlet valves

•  System diagnostics

Table 1

•  Aftertreatment low temperature regeneration

1204E-E44TA and  1204E-E44TTA Engine

Specifications

For more information on electronic engine features,

refer to the Operation and Maintenance  Manual,

“Features and Controls” topic (Operation Section).

Operating Range (rpm)

800 to  2200

(1)

4 In-Line

Number of Cylinders

Bore

105 mm (4.13 inch)

127 mm (4.99 inch)

Engine Diagnostics

Stroke

Power

The engine has built-in diagnostics in order to ensure

that the engine systems are functioning correctly. The

operator will be alerted to the condition by a “Stop or

Warning” lamp. Under certain conditions, the engine

horsepower and the vehicle speed may be limited.

The electronic service tool may be used to display

the diagnostic codes.

MK

60  to 110  kW

(80.46 to 147.51 hp)

ML

105  to129.5 kW

(140.805 to 173.65 hp)

Aspiration

MK Single Turbocharged

charge cooled

ML Series Turbocharged

charge cooled

There are three types of diagnostic codes: active,

logged, and event.

Most of the diagnostic codes are logged and stored

in the ECM. For  additional information, refer to

the Operation and Maintenance Manual, “Engine

Diagnostics” topic (Operation Section).

Compression Ratio

Displacement

16.5:1

4.4 L (268.504 cubic inch)

1-3-4-2

Firing Order

Rotation (flywheel end)

Counterclockwise

The ECM provides an  electronic governor that

controls the injector output in order to maintain the

desired engine rpm.

(1)  The operating rpm is dependent on the  engine rating, the

application, and the configuration of the throttle.

Engine Cooling and Lubrication

The cooling system and lubrication system consists

of the following components:

•  Gear-driven centrifugal water pump

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SEBU8605-01

Product Information Section

Model Views

•  Water temperature regulator which regulates the

engine coolant temperature

Expected engine life is generally predicted by the

average power that is demanded. The average power

that is demanded is based on fuel consumption of the

engine over a period. Reduced hours of operation

at full throttle and/or operating at reduced  throttle

settings result in a lower average power demand.

Reduced hours of operation will increase the length of

operating time before an engine overhaul is required.

•  Gear-driven rotor type oil pump

•  Oil cooler

The engine lubricating oil is supplied by a rotor type

oil pump. The engine lubricating oil is cooled and the

engine lubricating oil is filtered. The bypass  valve

can provide unrestricted flow of  lubrication oil to

the engine if the oil filter element  should become

plugged.

Aftermarket Products and Perkins

Engines

Perkins does not warrant the quality or performance

Engine efficiency, efficiency of emission controls, and

engine performance depend on adherence to proper

operation and maintenance recommendations.

Engine performance and efficiency also depend on

the use of recommended fuels, lubrication oils, and

coolants. Refer to this Operation and Maintenance

Manual, “Maintenance Interval Schedule” for more

information on maintenance items.

of non-Perkins fluids and filters.

When auxiliary devices, accessories, or consumables

(filters, additives, catalysts,) which are made by other

manufacturers are used on Perkins products, the

Perkins warranty is not affected simply because of

such use.

However, failures that result from the installation

or use  of other manufacturers  devices,

accessories, or consumables are NOT Perkins

defects. Therefore, the defects are NOT covered

under the Perkins warranty.

Aftertreatment System

The aftertreatment system is approved for use by

Perkins. In order to be emission-compliant only the

approved Perkins aftertreatment system must be

used on a Perkins engine.

Clean Emission Module (CEM)

The CEM comprises of two main components in a

single unit, the Diesel Oxidation Catalyst DOC and

the Diesel Particulate Filter DPF. The function of the

CEM is to ensure that the  engine exhaust meets

the required emissions regulation for the country of

operation.

The engine exhaust is connected by a flexible pipe to

the CEM. The exhaust gases pass through the DOC

in order to remove contaminants, carbon monoxide,

and hydrocarbons. The exhaust gases then enter the

DPF where any particulate matter soot and ash will

be trapped.

The CEM uses a passive regeneration process to

ensure that normal operation of the engine removes

the soot. The soot is removed at  an equal rate of

which the soot is captured. The ash remains in the

DPF and must be removed at an engine overhaul.

Engine Service Life

Engine efficiency and maximum utilization of engine

performance depend on the adherence to  proper

operation and maintenance recommendations. In

addition, use recommended fuels, coolants,  and

lubricants. Use the Operation and  Maintenance

Manual as a guide for required engine maintenance.

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SEBU8605-01

27

Product Information Section

Product Identification Information

Product Identification

Information

i03865704

Plate Locations and  Film

Locations

(Engine Aftertreatment System

)

g02109488

Illustration 25

Typical example

The module arrangement exhaust plate is installed

on the mounting plate  (1). The location of  the

arrangement plate mounting  plate can alter

depending on the application.

Record the information that is  on the plate. This

information identifies the engine  aftertreatment

system. This information will be required  by your

Perkins distributor. The information is essential in

order to be emissions complaint.

g02109493

Illustration 26

Module Arrangement Exhaust Plate

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SEBU8605-01

Product Information Section

Product Identification Information

i03827189

Serial Number Plate (1)

Plate Locations and  Film

Locations

(Engine)

The engine serial number plate is located  on the

left side of the cylinder block to the rear of the front

engine mounting.

g02101733

Illustration 28

Serial number plate

i03867276

Reference Numbers

g02077373

Illustration 27

Information for the following items may be needed to

order parts. Locate the information for your engine.

Record the information in the appropriate space.

Make a copy of  this list for a record.  Keep the

information for future reference.

Perkins engines are identified by an engine serial

number.

An example  of an  engine number  is

ML*****U000001U.

Record for Reference

***** ____________________The list number for the engine

ML _____________________________________The type of engine

U ____________________________Built in the United Kingdom

000001 ___________________________Engine Serial Number

U _____________________________________Year of Manufacture

Engine Model  _______________________________________________

Engine Serial number  _____________________________________

Engine Low Idle rpm  ______________________________________

Engine Full Load rpm  _____________________________________

Primary Fuel Filter  _________________________________________

Water Separator Element  ________________________________

Secondary Fuel Filter Element  __________________________

Lubrication Oil Filter Element  ___________________________

Auxiliary Oil Filter Element  _______________________________

Total Lubrication System Capacity  _____________________

Total Cooling System Capacity  _________________________

Air Cleaner Element  _______________________________________

Perkins dealers or Perkins distributors need all of

these numbers in order to determine the components

that were included with the engine. This information

permits accurate identification of replacement part

numbers.

The numbers for fuel setting information for electronic

engines are stored within  the flash file. These

numbers can be read by using the electronic service

tool.

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SEBU8605-01

29

Product Information Section

Product Identification Information

Drive Belt  ____________________________________________________

Engine Aftertreatment System

Part Number  ________________________________________________

Serial Number  ______________________________________________

i04274850

Emissions Certification Film

An emission label is installed on the front gear cover.

Note: A second emission label will be supplied with

the engine. If necessary, the second emission label

will be installed on the application  by the original

equipment manufacturer.

g02443596

Illustration 29

Typical example

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SEBU8605-01

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

Some removals require lifting the fixtures in order to

obtain correct balance and safety.

To remove the engine ONLY, use the lifting eyes that

are on the engine.

Lifting eyes are designed and installed for specific

engine arrangements. Alterations to the lifting eyes

and/or the engine make the lifting eyes and the lifting

fixtures obsolete. If alterations are made,  ensure

that correct lifting devices are  provided. Consult

your Perkins dealer or your Perkins distributor for

information regarding fixtures for correct  engine

lifting.

i04332972

Product Lifting

(Engine)

g01097527

Illustration 30

NOTICE

Never bend the eyebolts and the brackets. Only load

the eyebolts and the brackets under tension. Remem-

ber that the capacity of an eyebolt is less as the angle

between the supporting members and  the object be-

comes less than 90 degrees.

When it  is necessary to  remove a component at  an

angle, only use a link bracket that is properly rated for

the weight.

Use a hoist to  remove heavy components. Use

an adjustable lifting beam  to lift the engine. All

supporting members (chains and cables) should be

parallel to each other. The chains and cables should

be perpendicular to the top of the object that is being

lifted.

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SEBU8605-01

31

Operation Section

Lifting and Storage

Industrial Open Power Unit

g02488437

Illustration 31

Typical example

(1) Location of front lifting eye

(2) Location of rear lifting eye

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SEBU8605-01

Operation Section

Lifting and Storage

i04195469

i04084189

Product Lifting

(Clean Emission Module)

Product Storage

(Engine and Aftertreatment)

Perkins are not responsible for damage which may

occur when an engine is in storage after a period in

service.

Your Perkins dealer or your Perkins distributor can

assist in preparing the engine for extended storage

periods.

Condition for Storage

The engine must be stored in a water proof building.

The building must be kept at a constant temperature.

Engines that are filled with Perkins ELC  will have

coolant protection to an ambient  temperature of

−36° C (−32.8° F). The engine must not be subjected

to extreme variations in temperature and humidity.

Storage Period

An engine can be stored for up to 6 months provided

all the recommendation are adhered to.

g02385036

Illustration 32

Ensure that the correct clothing  is worn, refer to

this Operation and Maintenance Manual, “General

Hazard Information”.

Storage Procedure

Keep a record of  the procedure that has been

completed on the engine.

The weight of the clean emission  module (CEM)

when laden is approximately 50 kg  (110 lb). Two

suitable double looped slings are required in order to

lift the CEM. Also a suitable hoist will be required in

order to remove and install the assembly.

Note: Do not store an engine that has biodiesel in

the fuel system.

1.  Ensure that the engine is clean and dry.

The slings must be  attached to the CEM in the

positions as shown in illustration 32.

a.  If the engine has been operated using biodiesel,

the system must be drained and  new filters

installed. The fuel tank will require flushing.

Ensure that the slings only contact the body of the

CEM. A test lift may be required in order to achieve

the correct balance of the assembly.

b. Fill the fuel system with an ultra low sulfur fuel.

For more information on acceptable fuels refer

to this Operation and Maintenance Manual,

“Fluid recommendations”. Operate the engine

for 15 minutes in order to remove all biodiesel

from the system.

Some applications may require a frame or jig in order

to lift the CEM. A frame or jig must only be connected

to the cradle of the CEM. Refer to the OEM for more

information.

2.  Drain any water from the primary  filter water

separator. Ensure that the fuel tank is full.

3.  The engine oil will not need  to be drained in

order to store the engine. Provided the  correct

specification of engine oil is  used the engine

can be stored  for up to 6  months. For the

correct specification of engine oil  refer to this

Operation and Maintenance Manual,  “Fluid

recommendations”.

This document is printed from SPI². Not for RESALE

SEBU8605-01

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Operation Section

Lifting and Storage

4.  Remove the drive belt from the engine.

Sealed Coolant System

Ensure that the cooling system is filled with Perkins

ELC, or an antifreeze that meets  “ASTM D6210”

specification.

Open Cooling System

Ensure that all  cooling drain plugs have been

opened. Allow the coolant to drain. Install the drain

plugs. Place a vapor phase inhibitor into the system.

The coolant system must be sealed once the vapor

phase inhibitor has been introduced. The effect of the

vapor phase inhibitor will be lost if the cooling system

is open to the atmosphere.

For maintenance procedures ref to this Operation

and Maintenance Manual.

Aftertreatment

No special procedures are required. The exhaust

outlet of the aftertreatment should be capped. Before

storing, the engine and the aftertreatment must be

enclosed in a cover.

Monthly Checks

The crankshaft must be rotated in order to change

the spring loading  on the valve train.  Rotate

the crankshaft more than  180 degrees. Visibly

check for damage or corrosion to the  engine and

aftertreatment.

Ensure that the engine  and aftertreatment are

covered completely before  storage. Log the

procedure in the record for the engine.

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34

SEBU8605-01

Operation Section

Gauges and Indicators

Gauges and Indicators

1.  Remove the load.

2.  Stop the engine.

i04220531

3.  Check and maintain the oil level.

Gauges and Indicators

Jacket Water Coolant Temperature  –

Typical temperature range is 82° to 94°C

(179.6° to 201.2°F). This temperature range

will vary according to engine load and the ambient

temperature.

Your engine may not have the same gauges or all of

the gauges that are described. For more information

about the gauge package, see the OEM information.

A 100 kPa (14.5 psi) radiator cap must be installed

on the cooling system. The maximum temperature

for the cooling system is 108°  C (226.4° F). This

temperature is measured  at the outlet for the

water temperature regulator. The engine  coolant

temperature is regulated by the  engine sensors

and the engine ECM. This programming cannot be

altered. An engine derate can occur if the maximum

engine coolant temperature is exceeded.

Gauges provide indications of engine performance.

Ensure that the gauges are in good working order.

Determine the normal operating range by observing

the gauges over a period of time.

Noticeable changes in gauge  readings indicate

potential gauge or engine problems. Problems may

also be indicated by gauge readings that  change

even if the  readings are within specifications.

Determine and correct the cause of any significant

change in the  readings. Consult your Perkins

distributor for assistance.

If the engine is operating above the normal range,

reduce the engine load. If high coolant temperatures

are a frequent  event, perform the  following

procedures:

Some engine applications are equipped with Indicator

Lamps. Indicator lamps can be used as a diagnostic

aid. There are two lamps. One lamp has an orange

lens and the other lamp has a red lens.

1.  Reduce the load and the engine rpm.

2.  Determine if the engine must  be shut down

immediately or if the engine can  be cooled by

reducing the load.

These indicator lamps can be used in two ways:

•  The indicator lamps can be used to  identify the

current operational status of  the engine. The

indicator lamps can also indicate that the engine

has a fault. This system is automatically operated

via the ignition switch.

3.  Inspect the cooling system for leaks. If necessary,

consult your Perkins distributor for assistance.

Tachometer  – This gauge indicates engine

speed (rpm). When the throttle control lever

is moved to the full throttle position without

load, the engine is running at high idle. The engine is

running at the full load rpm when the throttle control

lever is at the full throttle  position with maximum

rated load.

•  The indicator lamps can be used to identify active

diagnostic codes. This system  is activated by

pressing the Flash Code button.

Refer to the Troubleshooting  Guide, “Indicator

Lamps” for further information.

NOTICE

Operation at speeds exceeding  high idle rpm should

be kept to a minimum. Overspeeding can result in se-

rious damage to the engine.

NOTICE

If no  oil pressure  is  indicated, STOP  the engine.  If

maximum  coolant temperature  is  exceeded, STOP

the engine. Engine damage can result.

Ammeter  – This gauge indicates the

amount of charge or  discharge in the

battery charging circuit. Operation of the

indicator should be to the “+” side of “0” (zero).

Engine Oil Pressure  – The oil pressure

should be greatest after a cold engine is

started. The typical engine oil pressure with

SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) at rated

rpm.

Fuel Level  – This gauge indicates the fuel

level in the fuel tank. The fuel level gauge

operates when the “START/STOP” switch

is in the “on” position.

A lower oil pressure is normal at low idle. If the load

is stable and the gauge reading changes, perform

the following procedure:

This document is printed from SPI². Not for RESALE

SEBU8605-01

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Operation Section

Gauges and Indicators

•  Oil pressure

Service Hour Meter – The gauge indicates

total operating hours of the engine.

•  Intake temperature

•  Intake pressure

•  Atmospheric pressure

•  Fuel temperature

Indicator Lamps

There is four indicator lamps that are available.

•  Shutdown Lamp

•  Warning Lamp

•  Wait to Start Lamp

•  Low Oil Pressure Lamp

For information, refer to this manual,  “Monitoring

System (Table for the  Indicator Lamps)” for the

sequence of operation of the shutdown lamp and the

warning lamp.

The function of the wait to start lamp is automatically

controlled at engine start-up.

The function of the low oil pressure lamp is controlled

by the engine ECM. If low oil pressure is detected,

the lamp will be illuminated.  The reason for the

illumination of the low-pressure lamp  should be

investigated immediately.

All lamps will illuminate for 2  seconds in order to

check that the lamps  are functioning when the

keyswitch is turned to the ON position. If any of the

lamps stay illuminated, the reason for illumination

should be investigated immediately.

Instrument panels and Displays

In order to monitor  the engine a wide verity  of

instrument panels are available. These instrument

panels can contain the  indicator lamps and the

gauges for the application.

Also available  are mini power displays  and

performance monitors. These displays and monitors

can show the  operator the following  engine

information.

•  The system configuration parameters

•  The customer specified parameters

•  Diagnostic codes

•  Event codes

•  Coolant temperature

•  Oil temperature

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36

SEBU8605-01

Operation Section

Features and Controls

Features and Controls

Programmable Options  and

Systems Operation

i04340829

Monitoring System

If the  Warning/Derate/Shutdown mode  has been

selected  and   the  warning   indicator  activates,

bring the engine to a stop whenever possible. De-

pending on  the  application, special  precautions

should be taken to avoid personal injury.

If the Shutdown mode has been selected  and the

warning indicator activates, engine shutdown may

take as little as 20 seconds from the time the warn-

ing indicator  is activated.  Depending on  the ap-

plication, special precautions should  be taken to

avoid personal injury. The engine can be restarted

following shutdown for emergency maneuvers, if

necessary.

The engine can be programmed to  the following

modes:

“Warning”

The orange “Warning” lamp will turn “ON” and the

warning signal is activated continuously in order to

alert the operator that one or  more of the engine

parameters is not within normal operating range.

NOTICE

The  Engine Monitoring  System  is not  a  guarantee

against  catastrophic   failures.  Programmed  delays

and derate schedules are designed to minimize false

alarms and provide  time for the operator  to stop the

engine.

“Derate”

The orange warning lamp will be flashing. After the

warning, the engine power will be derated.

The engine will be derated if the  engine exceeds

preset operational limits. The  engine derate is

achieved by restricting the amount of  fuel that is

available for each injection.  The amount of this

reduction of fuel is dependent on the severity of the

fault that has caused the engine derate, typically up

to a limit of 50%. This reduction in fuel results in a

predetermined reduction in engine power.

The following parameters are monitored:

•  Coolant temperature

•  Intake manifold air temperature

•  Intake manifold air pressure

•  Oil pressure

“Shutdown”

•  Pressure in the fuel rail

The orange warning lamp will be flashing and the red

shutdown lamp will be on solid. After the warning,

the engine power will be derated. The engine  will

continue at the rpm of the set derate until a shutdown

of the engine occurs. The engine can be restarted

after a shutdown for use in an emergency.

•  Engine speed/timing

•  Fuel temperature

•  Atmospheric pressure (Barometric pressure)

•  The Inlet pressure and outlet pressure of the NOx

reduction system

A shutdown of the engine  may occur in as little

as 20 seconds. The engine can be restarted  after

a shutdown for use in  an emergency. However,

the cause of the initial  shutdown may still exist.

The engine may shut down again in as little as 20

seconds.

•  Temperature of the NOx reduction system

•  Water in fuel switch

•  The amount of soot in the Diesel particulate filter

If there is a signal  for high coolant temperature,

there will be a 2 second delay in order to verify the

condition.

If there is a signal for low oil pressure, there will be a

2 second delay in order to verify the condition.

This document is printed from SPI². Not for RESALE

&, nbsp;

SEBU8605-01

37

Operation Section

Features and Controls

For information on the operation of the warning lamps

and the shutdown lamp, refer to this Operation and

Maintenance Manual, “ Monitoring System (Table

for Indicator Lamps)”. For each of the programmed

modes, refer to Troubleshooting Guide, “Indicator

Lamps” for more information on Indicator Lamps.

For more information or  assistance for repairs,

consult your Perkins distributor  or your Perkins

dealer.

This document is printed from SPI². Not for RESALE

38

SEBU8605-01

Operation Section

Features and Controls

i04201172

Monitoring System

(Table for the Indicator lamps)

Note: When in operation the amber warning lamp

has three states, solid, flashing, and fast flashing.

The sequence is to give a visual  indication of the

importance of the warning. Some application can

have an audible warning installed.

Ensure that the engine maintenance is carried out at

the correct intervals. A lack of maintenance can result

in illumination of the warning lamp. For the correct

intervals of maintenance, refer to  the Operation

and Maintenance Manual, “Maintenance Interval

Schedule”.

Table 2

Warning

Lamp

Shutdown

Lamp

Lamp State

Description of the Indication

Engine Status

The keyswitch is in the ON position but

On

On

Lamp Check

When the keyswitch is moved to the

ON position, the lamps come on for 2    the engine has not yet been cranked.

seconds and the lamps will then go

off.

Off

Off

Off

No Faults

Warning

With the engine in operation, there

are no active warnings, diagnostic

codes, or event codes.

The engine is operating with no detected

faults.

On Solid

Level 1 warning

The engine is operating normally but

there is one or  more faults with the

electronic management system for the

engine.

Flashing

Flashing

Off

On

Warning

Level 2 warning

The engine continues to be operated,

but the level  of importance of the

warning has increased.

Depending on the particular fault and

the severity the engine may be de-rated.

The engine could  be damaged if

continued to be operated.

Engine

Shutdown

Level 3 warning

The engine is either shutdown or  an

engine shutdown is imminent. One or

more monitored engine parameters

have exceeded the limit for an engine

shutdown. This pattern of lamps can be

caused by the detection of a serious

active diagnostic code.

If both the warning  lamp and the

shutdown lamp are in operation, this

issue indicates one of the following

conditions.

1. One or more  of the shutdown

values for the  engine protection

strategy has been exceeded.

2. A serious active diagnostic code

has been detected.

After a short time period, the engine

may shut down.

This document is printed from SPI². Not for RESALE

SEBU8605-01

39

Operation Section

Features and Controls

i04215952

Sensors and  Electrical

Components

(Aftertreatment)

The illustration within  the section shows  the

typical locations of the sensors and other electrical

components on the industrial engine. Specific engine

aftertreatment systems may appear different due to

the application.

g02395776

Illustration 33

(1) Temperature Sensor

(2) Connector for Temperature Sensor

(3) Soot Sensor Connection

(4) Aftertreatment Identification Module

(5) Soot Sensor Connection

(6) Soot Sensor

Note: The location of the soot sensor will  depend

i04238530

on the application.

Sensors and  Electrical

Components

The illustration within  the section shows the

typical locations of the sensors and other electrical

components on a 1204 Industrial engine. Specific

engines may appear different due to the application.

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40

SEBU8605-01

Operation Section

Features and Controls

g02411637

Illustration 34

(1) Coolant Temperature Sensor

(2) Fuel  Pressure Sensor (Fuel Rail

Pressure Sensor)

(3) Intake Manifold Air Temperature Sensor

(4) Intake Manifold Pressure Sensor

(5) Electronic Control Module (ECM)

(6) Atmospheric  Pressure Sensor

(Barometric Pressure Sensor)

(7) Primary  Speed/Timing sensor

(Crankshaft Position Sensor)

(8) Diagnostic Connector

(9) Oil Pressure Sensor

(10) Fuel Temperature Sensor

(11) Solenoid for the High  Pressure Fuel

Pump

(13) Inlet Pressure  Sensor for the NOx

Reduction System (NRS)

(14) Outlet Pressure Sensor for the NRS

(15) Control Valve for the NRS

(16) Temperature Sensor for the NRS

(12) Wastegate Regulator

This document is printed from SPI². Not for RESALE

SEBU8605-01

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Operation Section

Features and Controls

g02411837

Illustration 35

(17) Back Pressure Valve

(18) Alternator

(19) Secondary Speed/Timing  Sensor

(Camshaft Position Sensor)

(20) Starting Motor

(21) Water in Fuel Switch

(22) Oil Level Switch (if Equipped)

(23) Electric Priming Pump

g02413838

Illustration 36

(1) Coolant Temperature Sensor

(2) Fuel  Pressure Sensor (Fuel Rail

Pressure Sensor)

(3) Intake Manifold Air Temperature Sensor

(4) Intake Manifold Pressure Sensor

(5) Electronic Control Module (ECM)

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42

SEBU8605-01

Operation Section

Features and Controls

g02413839

Illustration 37

(6) Atmospheric  Pressure Sensor

(Barometric Pressure Sensor)

(7) Primary  Speed/Timing sensor

(Crankshaft Position Sensor)

(8) Diagnostic Connector

(9) Oil Pressure Sensor

g02413840

Illustration 38

(10) Fuel Temperature Sensor

(11) Solenoid for the High  Pressure Fuel

Pump

(12) Wastegate Regulator

(13) Inlet Pressure  Sensor for the NOx

Reduction System (NRS)

(14) Outlet Pressure Sensor for the NRS

This document is printed from SPI². Not for RESALE

SEBU8605-01

43

Operation Section

Features and Controls

g02414076

Illustration 39

(15) Control Valve for the NRS

(16) Temperature Sensor for the NRS

(17) Back Pressure Valve

g02414077

Illustration 40

(18) Alternator

(19) Secondary Speed/Timing  Sensor

(Camshaft Position Sensor)

(20) Starting Motor

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44

SEBU8605-01

Operation Section

Features and Controls

g02414506

Illustration 41

(21) Water in Fuel Switch

(22) Oil Level Switch (if Equipped)

(23) Electric Priming Pump

•  Types and locations of the shutoff

i04372832

Engine Shutoffs and Engine

Alarms

•  Conditions which cause each shutoff to function

•  The resetting procedure that is required to restart

the engine

Alarms

Shutoffs

The alarms are electrically operated. The operation

of the alarms is controlled by the ECM.

The shutoffs are electrically operated or mechanically

operated. The electrically operated shutoffs  are

controlled by the ECM.

The alarm is operated by a sensor or by a  switch.

When the sensor or the switch is activated, a signal

is sent to the ECM. An  event code is created by

the ECM. The ECM will send  a signal in order to

illuminate the lamp.

Shutoffs are set at critical levels  for the following

items:

•  Operating temperature

•  Operating pressure

•  Operating level

Your engine may be equipped  with the following

sensors or switches:

Coolant level  – The low coolant  level switch

indicates when the coolant level is low.

•  Operating rpm

Coolant temperature  – The coolant temperature

sensor indicates  high jacket water coolant

temperature.

The particular shutoff may need to be reset before

the engine will start.

NOTICE

Intake manifold air temperature  – The intake

manifold air temperature sensor indicates high intake

air temperature.

Always determine the cause of the engine shutdown.

Make necessary  repairs before attempting to  restart

the engine.

Be familiar with the following items:

This document is printed from SPI². Not for RESALE

SEBU8605-01

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Operation Section

Features and Controls

Intake manifold pressure  – The intake manifold

pressure sensor checks the rated pressure in the

engine manifold.

i03554501

Overspeed

Fuel rail pressure  – The fuel rail pressure sensor

checks for high pressure or low pressure in the fuel

rail.

•  ECM ______________________Electronic Control Module

•  RPM ________________________ Revolutions Per Minute

Engine oil pressure  – The engine oil pressure

sensor indicates when oil pressure drops below rated

system pressure, at a set engine speed.

An overspeed is detected  by the speed/timing

sensors.

Engine overspeed  – If the engine rpm exceeds the

overspeed setting, the alarm will be activated.

The default setting for an overspeed is 3000 rpm.

The ECM will cut the power  to the electronic unit

injectors, until the rpm drops below 200 rpm of the

overspeed setting. A diagnostic fault code will  be

logged into the ECM memory and a warning lamp will

indicate a diagnostic fault code.

Air filter restriction  – The switch checks the air

filter when the engine is operating.

User-Defined switch  – This switch can shut down

the engine remotely.

An overspeed can be set from 2600 rpm to 3000 rpm.

This setting depends on the application.

Water in fuel switch  – This switch checks for water

in the primary fuel filter when the engine is operating.

Fuel temperature   – The fuel temperature sensor

monitors the pressurized fuel in the high-pressure

fuel pump.

Note: The  sensing element of the  coolant

temperature switch must be submerged in coolant

in order to operate.

Engines may be equipped  with alarms in order

to alert the operator when undesirable  operating

conditions occur.

NOTICE

When an alarm is activated, corrective measures must

be taken before the situation becomes an emergency

in order to avoid possible engine damage.

If corrective measures  are not taken within a

reasonable time, engine damage could result. The

alarm will continue until the condition is corrected.

The alarm may need to be reset.

Testing

Turning the keyswitch to the ON position will check

the indicator lights on  the control panel. All the

indicator lights will be illuminated for 2 seconds after

the keyswitch is operated. Replace suspect bulbs

immediately.

Refer to Troubleshooting, KENR9116  for more

information.

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46

SEBU8605-01

Operation Section

Engine Diagnostics

Engine Diagnostics

i04215570

Diagnostic Flash  Code

Retrieval

i02651093

Self-Diagnostics

Use the “DIAGNOSTIC” lamp or an electronic service

tool to determine the diagnostic flash code.

Perkins electronic engines have the capability  to

perform a self-diagnostics test. When the system

detects an active  problem, a diagnostic lamp

is activated. Diagnostic codes  will be stored in

permanent memory in the Electronic Control Module

(ECM). The diagnostic codes  can be retrieved

by using the  electronic service tool. Refer  to

Troubleshooting , “Electronic Service  Tools” for

further information.

Use the following procedure to retrieve  the flash

codes if the engine is equipped with a “DIAGNOSTIC”

lamp:

1.  Move the keyswitch from the on/off two  times

within 3 seconds.

A flashing YELLOW lamp indicates a 3-digit code for

the engine. The sequence of flashes represents the

system diagnostic message. Count the first sequence

of flashes in order to determine the first digit of the

flash code. After a two second pause, the second

sequence of flashes will identify the second digit of

the flash code. After the second  pause, the third

sequence of flashes will identify the flash code.

Some installations have electronic displays  that

provide direct readouts of the  engine diagnostic

codes. Refer to  the manual that  is provided

by the OEM for  more information on retrieving

engine diagnostic codes.  Alternatively refer to

Troubleshooting , “Indicator Lamps”  for further

information.

Table 3

Active codes represent problems that currently exist.

Flash Code  Table

These problems should be investigated first.

Description

Flash Code

Logged codes represent the following items:

•  Intermittent problems

Injector fault

111

Injector number 2 current out of range

Injector number 3 current out of range

Injector number 4 current out of range

112

113

114

115

•  Recorded events

•  Performance history

Injector number 5 current out of range

(6 cylinder only)

The problems may have been repaired since  the

logging of the code. These codes do not indicate that

a repair is needed. The codes are guides or signals

when a situation exists. Codes may be  helpful to

troubleshoot problems.

Injector number 6 current out of range

(6 cylinder only)

116

133

Intake manifold air  temperature

sensor out of range

When the problems have  been corrected, the

corresponding logged fault codes should be cleared.

Engine speed sensor out of range

Engine timing offset fault

141

143

144

Engine operation mode  selector

switch erratic,  intermittent, or

incorrect

i02651107

Diagnostic Lamp

High air filter restriction - Warning

151

152

Atmospheric pressure sensor out of

range

A diagnostic lamp is used to indicate the existence of

an active fault. Refer to Troubleshooting , “Indicator

Lamps” for more information. A  fault diagnostic

code will remain active until the problem is repaired.

The diagnostic code may be retrieved by using the

electronic service tool. Refer to Troubleshooting ,

“Electronic Service Tools” for more information.

Throttle position sensor out of range

154

155

Secondary throttle position sensor

out of range

Oil pressure sensor out of range

157

(continued)

This document is printed from SPI². Not for RESALE

SEBU8605-01

47

Operation Section

Engine Diagnostics

(Table 3, contd)

(Table 3, contd)

Fuel rail pressure sensor out of range

159

165

168

8 V DC Supply voltage out of range

517

527

Programmed parameter fault erratic,

intermittent, or incorrect

Fuel temperature sensor out of range

5 Volt Sensor DC Power Supply #2

out of range

528

551

Engine coolant temperature sensor

out of range

No diagnostic code detected

Low Engine  Coolant Level -

Shutdown

169

Refer to Troubleshooting, “Diagnostic Flash Code

Cross Reference” for more information.

Turbo wastegate drive out of range

177

197

Intake manifold pressure sensor out

of range

i01902949

Glow plug start aid  relay current

above normal

199

224

Fault Logging

Diesel Particulate Filter DPF Intake

temperature sensor out of range

DPF Soot sensors out of range

226

227

The system provides the capability of Fault Logging.

When the Electronic  Control Module (ECM)

generates an active diagnostic code, the code will

be logged in the memory of the  ECM. The codes

that have been logged by the ECM can be identified

by the electronic service tool. The active codes that

have been logged will be cleared  when the fault

has been rectified or the fault is  no longer active.

The following logged faults can not be cleared from

the memory of the ECM  without using a factory

password: Overspeed, low engine oil pressure, and

high engine coolant temperature.

Exhaust gas  recirculation

temperature/pressure out of range

Exhaust gas recirculation  valve

control current out of range

228

229

231

232

233

245

246

247

249

253

415

426

Exhaust gas recirculation  valve

control voltage out of range

Exhaust gas recirculation pressure

sensor out of range

Air inlet temperature sensor voltage

out of range

Ether injection control solenoid out of

range

Idle validation switch  #1 erratic,

intermittent, or incorrect

Idle validation switch  #2 erratic,

intermittent, or incorrect

Exhaust Gas Recirculation Outlet

Pressure Sensor out of range

Exhaust back pressure regulator

position voltage out of range

Engine Fuel Supply Lift Pump Relay

out of range

Personality module  erratic,

intermittent, or incorrect

Machine security system module

abnormal update rate

Ignition key switch loss of signal

Electrical System Voltage fault

429

511

514

SAE J1939 Data  Link abnormal

update rate

5 Volt sensor  DC power supply

voltage out of range

516

(continued)

This document is printed from SPI². Not for RESALE

48

SEBU8605-01

Operation Section

Engine Diagnostics

i03554534

i01902995

Engine Operation with Active

Diagnostic Codes

Engine Operation  with

Intermittent Diagnostic Codes

If a diagnostic lamp illuminates during normal engine

operation, the system has identified a situation that

is not within the specification. Use electronic service

tools to check the active diagnostic codes.

If a diagnostic lamp illuminates during normal engine

operation and the diagnostic  lamp shuts off, an

intermittent fault may have occurred. If a fault has

occurred, the fault will be logged into the memory of

the Electronic Control Module (ECM).

Note: If the customer has selected “DERATE” and if

there is a low oil pressure condition, the Electronic

Control Module (ECM) will limit the engine power

until the problem is corrected. If the oil pressure is

within the normal range, the engine may be operated

at the rated speed and load. However, maintenance

should be performed as soon as possible.

In most cases, it is not necessary to stop the engine

because of an intermittent  code. However, the

operator should retrieve the  logged fault codes

and the operator should reference the appropriate

information in order to identify the nature of the event.

The operator should log any observation that could

have caused the lamp to light.

The active diagnostic code should be investigated.

The cause of the problem should be corrected  as

soon as possible. If the cause of the active diagnostic

code is repaired  and there is only  one active

diagnostic code, the diagnostic lamp will turn off.

•  Low power

•  Limits of the engine speed

•  Excessive smoke, etc

Operation of the engine and  performance of the

engine can be limited  as a result of the  active

diagnostic code that is  generated. Acceleration

rates may be  significantly slower. Refer to the

Troubleshooting Guide for more information on the

relationship between these active diagnostic codes

and engine performance.

This information can be useful to help troubleshoot

the situation. The information can also be used for

future reference. For more information on diagnostic

codes, refer to the Troubleshooting Guide for this

engine.

i04217251

Configuration Parameters

The engine electronic control module (ECM) has

two types of configuration parameters. The system

configuration parameters and the customer specified

parameters.

The electronic service tool is required in order to alter

the configuration parameters.

System Configuration Parameters

System configuration parameters affect the emissions

of the engine or the power of  the engine. System

configuration parameters are programmed at the

factory. Normally, system configuration parameters

would never require  changing through the life

of the engine. System configuration  parameters

must be reprogrammed if  an ECM is replaced.

System configuration parameters do not  require

reprogrammed if the ECM software  is changed.

Factory passwords are required to change these

parameters.

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Operation Section

Engine Diagnostics

Table 4

System Configuration  Parameters

Configuration Parameters

Record

Full Load Setting

Full Torque Setting

Rating

Engine Serial Number

Factory Installed Aftertreatment Identification Number

DPF Soot Loading Sensing System Configuration Code

Limp Home Engine Speed Ramp Rate

ECM Software Release Date

Customer Specified Parameters

Customer specified parameters allow the engine to

be configured to the exact needs of the application.

The electronic service tool is required in order to alter

the customer configuration parameters.

Customer parameters may be changed repeatedly as

operational requirements change.

Table 5

Customer Specified  Parameters

Specified Parameters

Low Idle Parameters

Record

ECM Identification Parameter

Ether Solenoid Configuration

PTO and Throttle Lock Parameters

Throttle Lock Feature Installation Status

PTO Mode

Throttle Lock Engine Set Speed 1

Throttle Lock Engine Set Speed 2

Throttle Lock Increment Speed Ramp Rate

Throttle Lock Decrement Speed Ramp Rate

Throttle Lock Engine Set Speed Increment

Throttle Lock Engine Set Speed Decrement

Monitoring Mode Shutdowns

Monitoring Mode Derates

Limp Home Desired Engine Speed

Engine Acceleration Rate

Engine Speed Decelerating Ramp Rate

Coolant Level Switch

(continued)

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SEBU8605-01

Operation Section

Engine Diagnostics

(Table 5, contd)

Air Filter Restriction Switch Installation Status

Air Filter Restriction Switch Configuration

System Operating Voltage Configuration

Minimum Ambient Air Temperature

Maximum Ambient Air Temperature

Shutdown Enable Status

Shutdown Delay Time

Ambient Temperature Override Enable Status

Air Shutoff

Intermediate Engine Speed

Engine Fan Control

Engine Fan Type Configuration

Pulley Ratio

Temperature Error Increasing Hysteresis

Temperature Error Decreasing Hysteresis

Current Ramp Rate

Fan Speed

Top Fan Speed

Minimum Desired Fan Speed

Solenoid Minimum Current

Solenoid Maximum Current

Solenoid Dither Frequency

Solenoid Dither Amplitude

Charge Air Cooler Outlet Temperature Input Enable

Maximum Air Flow Charge Air Cooler Outlet Temperature

Minimum Air Flow Charge Air Cooler Outlet Temperature

Coolant Temperature Input Enable Status

Maximum Air Flow Coolant Temperature

Minimum Air Flow Coolant Temperature

Transmission Oil Temperature Input Enable Status

Maximum Air Flow Transmission Oil Temperature

Minimum Air Flow Transmission Oil Temperature

Hydraulic Oil Temperature Input Enable Status

Maximum Air Flow Hydraulic Oil Temperature

Minimum Air Flow Hydraulic Oil Temperature

Auxiliary #1 Temperature Input Enable Status

Maximum Air Flow Auxiliary #1 Temperature

Minimum Air Flow Auxiliary #1 Temperature

Auxiliary #2 Temperature Input Enable Status

(continued)

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Operation Section

Engine Diagnostics

(Table 5, contd)

Maximum Air Flow Auxiliary #2 Temperature

Minimum Air Flow Auxiliary #2 Temperature

Reversing Feature

Reverse Operation Early Termination Enable Status

Manual Purge

Suspend Purge

Purge Cycle Interval

Purge Cycle Duration

Coolant Level Switch

Air Filter Restriction Switch Installation Status

Air Filter Restriction Switch Configuration

Water in Fuel Switch Installation Status

User Defined Switch Installation Status

Auxiliary Temperature Sensor Installation Status

Auxiliary Pressure Sensor Installation Status

Diesel Particulate Filter Regeneration Force/Inhibit Switch

Installation

Remote Torque Speed Control Enable Status

System Operating Voltage Configuration

Customer Password 1

Customer Password 2

CAN Communication Protocol Write Security

CAN Communication Protocol Read Security

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SEBU8605-01

Operation Section

Engine Starting

Engine Starting

i04084389

Starting the Engine

i03648917

Before Starting Engine

Note: Do not adjust the engine speed control during

start-up. The electronic control module (ECM) will

control the engine speed during start-up.

S/N:  MK11-Up

Starting the Engine

Perform the required daily maintenance and other

periodic maintenance before the engine is started.

Inspect the engine compartment. This inspection can

help prevent major repairs at a later date. Refer to the

Operation and Maintenance Manual, “Maintenance

Interval Schedule” for more information.

1.  Disengage any equipment that is driven by the

engine.

2.  Turn the keyswitch to the RUN position. Leave the

keyswitch in the RUN position until the warning

light for the glow plugs is extinguished.

•  Ensure that the engine  has an adequate fuel

supply.

Note: During the key on, the  indicator lamps will

be illuminated for 2 seconds in order to check lamp

operation. If any of the  lamps do not illuminate,

replace the bulb.

•  Open the fuel supply valve (if equipped).

NOTICE

All valves in the fuel return line must be open and fuel

supply lines must be open. Damage to the fuel system

can occure if fuel  lines are closed with the  engine in

operation.

3.  When the warning light for the  glow plugs is

extinguished, turn the keyswitch to the START

position in order to engage the electric starting

motor and crank the engine.

Note: The operating period of the warning light for

the glow plugs will change due to the temperature

of the engine.

If the engine has not been started for several weeks,

fuel may have drained from  the fuel system. Air

may have entered the filter housing. Also, when fuel

filters 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

on priming the fuel system. Also, check that the fuel

specification is correct and that the fuel  condition

is correct. Refer to the Operation and Maintenance

Manual, “Fuel Recommendations”.

NOTICE

Do not  engage the  starting motor  when  flywheel is

turning. Do not start the engine under load.

If the engine fails  to start within 30 seconds, release

the starter  switch or button  and wait two  minutes to

allow the  starting motor to cool  before attempting to

start the engine again.

4.  Allow the keyswitch to return to the RUN position

after the engine starts.

Engine exhaust contains products of combustion

which may be harmful to your health. Always start

and operate  the engine  in a well  ventilated area

and, if in an enclosed area, vent the exhaust to the

outside.

5.  Repeat step 2 through step 4 if the engine fails

to start.

i03570564

•  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.

Cold Weather Starting

•  Reset all of the shutoffs or alarm components.

•  Ensure that any  driven equipment has been

disengaged. Minimize electrical loads or remove

any electrical loads.

Do not use aerosol types of starting aids such as

ether. Such use could  result in an explosion and

personal injury.

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Operation Section

Engine Starting

Startability will be improved at temperatures below

−18 °C (0 °F) from the use of a jacket water heater

or extra battery capacity.

7.  Operate the engine at low load until all systems

reach operating temperature. Check the gauges

during the warm-up period.

When Group 2 diesel fuel is used, the following items

provide a means of minimizing starting  problems

and fuel problems in cold weather: Engine oil pan

heaters, jacket water heaters, fuel heaters, and fuel

line insulation.

i03663103

Starting with  Jump Start

Cables

Use the procedure that follows  for cold weather

starting.

Note: Do not adjust the engine speed control during

start-up. The electronic control module (ECM) will

control the engine speed during start-up.

Improper jump start cable connections can cause

an explosion resulting in personal injury.

1.  Disengage any driven equipment.

Prevent sparks  near the  batteries. Sparks  could

cause vapors to explode. Do not allow jump start

cable ends to contact each other or the engine.

2.  Turn the keyswitch to the RUN position. Leave the

keyswitch in the RUN position until the warning

light for the glow plugs is extinguished.

Note: If it is possible, first diagnose the reason for

the starting failure. Refer to Troubleshooting, “Engine

Will Not Crank and Engine Cranks But Will Not Start”

for further information. Make any necessary repairs.

If the engine will not start only due to the condition

of the battery, either charge the battery, or start the

engine by using another  battery with jump start

cables.

NOTICE

Do not  engage the  starting motor  when  flywheel is

turning. Do not start the engine under load.

If the engine fails  to start within 30 seconds, release

the starter  switch or button  and wait two  minutes to

allow the starting  motor to cool  before attempting to

start the engine again.

The condition of the battery can be rechecked after

the engine has been switched OFF.

3.  When the warning light for the glow  plugs is

extinguished turn the keyswitch to the  START

position in order to engage the electric  starting

motor and crank the engine.

NOTICE

Using a battery source  with the same voltage as the

electric starting  motor. Use  ONLY equal  voltage for

jump starting. The use of higher  voltage will damage

the electrical system.

Note: The operating period of the warning light for

the glow plugs will change due to the temperature

of the engine.

Do not reverse the battery cables. The alternator can

be damaged.  Attach ground  cable last  and remove

first.

4.  Allow the keyswitch to return to the RUN position

after the engine starts.

Turn all  electrical accessories OFF  before attaching

the jump start cables.

5.  Repeat step 2 through step 4 if the engine fails

to start.

Ensure that the main power switch is in the OFF posi-

tion before attaching the jump  start cables to the en-

gine being started.

Note: The engine should not be “raced” in order to

speed up the warm up process.

6.  Allow the engine to idle for three to five minutes, or

allow the engine to idle until the water temperature

indicator begins to rise.  When idling after the

engine has started in cold weather, increase the

engine rpm from 1000 to  1200 rpm. This will

warm up the engine more quickly.  Maintaining

an elevated low idle speed for extended periods

will be easier with  the installation of a hand

throttle. Allow the white smoke to disperse before

proceeding with normal operation.

1.  Turn the start switch on the stalled engine to the

OFF position. Turn off all the engine's accessories.

2.  Connect one positive end of the jump start cable

to the positive cable terminal of the discharged

battery. Connect the other positive end of the jump

start cable to the positive cable terminal of  the

electrical source.

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SEBU8605-01

Operation Section

Engine Starting

3.  Connect one negative end of the jump start cable

to the negative cable terminal of  the electrical

source. Connect the other negative end  of the

jump start cable to the  engine block or to the

chassis ground. This procedure helps to prevent

potential sparks from igniting the  combustible

gases that are produced by some batteries.

i02330138

After Starting Engine

Note: In ambient temperatures  from 0 to 60°C

(32 to 140°F), the warm-up time is  approximately

three minutes. In temperatures below 0°C (32°F),

additional warm-up time may be required.

Note: The engine ECM must be powered before the

starting motor is operated or damage can occur.

When the engine idles during warm-up, observe the

following conditions:

4.  Start the engine in the normal operating procedure.

Refer to this Operation and Maintenance Manual,

“Starting the Engine”.

Do not check the high pressure fuel lines with the

engine or the starting motor  in operation. If you

inspect the engine in operation,  always use the

proper inspection procedure in order  to avoid a

fluid penetration hazard. Refer to  Operation and

Maintenance Manual, “General hazard Information”.

5.  Immediately after the engine is started, disconnect

the jump start cables in reverse order.

After jump starting, the alternator may not be able to

fully recharge batteries that are severely discharged.

The batteries must be replaced or charged to  the

proper voltage with a battery charger after the engine

is stopped. Many batteries which are  considered

unusable are still rechargeable. Refer to Operation

and Maintenance Manual, “Battery - Replace” and

Testing and Adjusting Manual, “Battery - Test”.

•  Check for any fluid or for any air leaks at idle rpm

and at one-half full rpm (no load on the  engine)

before operating the engine under load. This is not

possible in some applications.

•  Allow the engine to idle for three to five minutes, or

allow the engine to idle until the water temperature

indicator begins to rise. Check all gauges during

the warm-up period.

Note: Gauge readings 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. Significant

changes in the readings should be investigated.

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Operation Section

Engine Operation

Engine Operation

Engine Operation and a DPF

During normal engine operation, the operator of the

engine may notice the lack of black smoke from the

exhaust system.

i03858430

Engine Operation

Passive regeneration is the process  that is used

by the DPF in order to remove soot from the DPF.

In some applications, the engine  idle speed will

automatically be increased in order to allow passive

regeneration to occur.

Proper 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.

The time that is needed  for the engine to reach

normal operating temperature can be less than the

time taken for a walk-around inspection of the engine.

The engine can be operated at the rated rpm after

the engine is started and after the engine reaches

operating temperature. The engine will reach normal

operating temperature sooner during a low engine

speed (rpm) and during a low-power demand. This

procedure is more effective than idling the engine

at no load. The  engine should reach operating

temperature in a few minutes.

Avoid excess idling. Excessive idling causes carbon

buildup, engine slobber, and soot  loading of the

Diesel Particulate Filter (DPF). These issues  are

harmful to the engine.

Gauge readings 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. Significant

changes in the readings should be investigated.

Reduction of Particulate Emissions

The Diesel Particulate  Filter (DPF) will reduce

particulate emissions. The DPF collects the soot and

any ash that is produced by the combustion in the

engine. During regeneration, the soot is converted

into a gas which is released into the atmosphere. The

Ash remains in the DPF.

The temperature of the  DPF must be above a

particular value in order for regeneration to occur.

The exhaust gas provides heat for the regeneration

process.

Passive Regeneration  – The engine provides

sufficient exhaust gas temperature for regeneration.

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SEBU8605-01

Operation Section

Engine Operation

i04018232

Fuel Conservation Practices

The efficiency of the  engine can affect the fuel

economy. Perkins design  and technology in

manufacturing provides maximum fuel efficiency in

all applications. Follow the recommended procedures

in order to attain optimum performance for the life

of the engine.

•  Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel

may overflow from the fuel tank. Inspect fuel lines for

leaks. Repair the fuel lines, as needed.

•  Be aware of the properties of the different fuels.

Use only the recommended fuels. Refer  to the

Operations and Maintenance  Manual, “Fuel

Recommendations”for further information.

•  Avoid unnecessary idling.

Shut off the engine rathe, r than idle for long periods of

time.

•  Observe the service indicator frequently. Keep the

air cleaner elements clean.

•  Ensure that the turbocharger is operating correctly.

For more information refer to this Operation and

Maintenance Manual , “Turbocharger - Inspect”

•  Maintain a good electrical system.

One faulty battery cell will overwork the alternator.

This fault will consume excess power and excess

fuel.

•  The belt should be in good condition. Refer to the

Systems Operation, Testing and Adjusting, “V-Belt

Test” for further information.

•  Ensure that all of the connections of the hoses are

tight. The connections should not leak.

•  Ensure that the  driven equipment is in good

working order.

•  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.

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Operation Section

Engine Stopping

Engine Stopping

Stopping the Engine

NOTICE

i03648931

After Stopping Engine

i02334873

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  immediately  after it  has  been

working under load, can result in overheating and ac-

celerated wear of the engine components.

Contact with  high pressure fuel  may cause fluid

penetration and  burn hazards. High pressure  fu-

el spray  may cause  a fire  hazard. Failure to  fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

Avoid accelerating the engine prior to shutting it down.

Avoiding  hot  engine  shutdowns  will  maximize  tur-

bocharger shaft and bearing life.

•  After the engine has stopped, you must wait for

10 minutes in order to allow the fuel pressure to

be purged from the high pressure fuel lines before

any service or repair is performed on the engine

fuel lines. If necessary, perform minor adjustments.

Repair any leaks from  the low pressure fuel

system and from the cooling,  lubrication or air

systems. Replace any high pressure fuel line that

has leaked. Refer to Disassembly and assembly

Manual, “Fuel Injection Lines - Install”.

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. Reduce the

engine speed (rpm) to low idle. Allow the engine

to idle for five 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.

•  Check the crankcase oil level. Maintain the oil level

between the “MIN” mark and the “MAX” mark on

the engine oil level gauge.

•  If the engine is equipped with a service hour meter,

note the reading. Perform the maintenance that

is in the Operation and  Maintenance Manual,

“Maintenance Interval Schedule”.

i01903586

Emergency Stopping

•  Fill the fuel  tank in order  to help prevent

accumulation of moisture in the fuel. Do not overfill

the fuel tank.

NOTICE

Emergency shutoff controls are for EMERGENCY use

ONLY. DO  NOT  use emergency  shutoff devices  or

controls for normal stopping procedure.

NOTICE

Only use antifreeze/coolant mixtures recommended in

the Refill Capacities and Recommendations topic that

is in this Operation and Maintenance Manual. Failure

to do so can cause engine damage.

The OEM may have equipped the application 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.

Pressurized System: Hot coolant  can cause seri-

ous burns. To open the cooling system filler  cap,

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure cap slowly  in order to  relieve the pres-

sure.

•  Allow the engine to cool. Check the coolant level.

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SEBU8605-01

Operation Section

Engine Stopping

•  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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Operation Section

Cold Weather Operation

Cold Weather Operation

•  Install the correct specification of engine lubricant

before the beginning of cold weather.

•  Check all rubber parts (hoses, fan  drive belts,)

weekly.

i04321989

Cold Weather Operation

•  Check all electrical wiring and connections for any

fraying or damaged insulation.

Perkins Diesel Engines can operate effectively in

cold weather. During cold weather, the starting and

the operation of the diesel engine is dependent on

the following items:

•  Keep all batteries fully charged and warm.

•  Fill the fuel tank at the end of each shift.

•  Check the air cleaners and the air  intake daily.

Check the air intake more often when you operate

in snow.

•  The type of fuel that is used

•  The viscosity of the engine oil

•  The operation of the glow plugs

•  Optional Cold starting aid

•  Ensure that the glow plugs are in working order.

Refer to Troubleshooting, “Glow Plug Starting Aid-

Test”.

•  Battery condition

Personal  injury  or property  damage  can  result

from alcohol or starting fluids.

This section will cover the following information:

•  Potential problems that are caused by cold-weather

operation

Alcohol or starting fluids are highly flammable and

toxic and if improperly stored could result in injury

or property damage.

•  Suggest steps which can be  taken in order to

minimize starting problems and operating problems

when the ambient air temperature  is between

0° to−40 °C (32° to 40 °F).

Do not use aerosol types of starting aids such as

ether. Such use could  result in an explosion and

personal injury.

The operation and maintenance of  an engine in

freezing temperatures is complex . This complexity is

because of the following conditions:

•  Weather conditions

•  Engine applications

•  For jump starting with cables  in cold weather,

refer to the Operation and Maintenance Manual,

“Starting with Jump Start Cables.” for instructions.

Recommendations from your Perkins  dealer or

your Perkins distributor are based on past proven

practices. The information  that is contained in

this section provides guidelines for cold-weather

operation.

Viscosity of the Engine Lubrication

Oil

Correct engine oil viscosity is essential. Oil viscosity

affects the amount of  torque that is needed to

crank the engine.  Refer to this Operation and

Maintenance Manual, “Fluid Recommendations” for

the recommended viscosity of oil.

Hints for Cold Weather Operation

•  If the engine will start, operate the engine until a

minimum operating temperature of 80° C (176° F)

is achieved. Achieving operating temperature will

help prevent the intake valves and exhaust valves

from sticking.

Recommendations for the Coolant

Provide cooling system protection for  the lowest

expected outside temperature. Refer to this Operation

and Maintenance Manual, “Fluid Recommendations”

for the recommended coolant mixture.

•  The cooling system and the lubrication  system

for the engine do not lose heat immediately upon

shutdown. This means that an engine can be shut

down for a period and the engine can still have the

ability to start readily.

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SEBU8605-01

Operation Section

Cold Weather Operation

In cold weather, check  the coolant often for the

correct glycol concentration in  order to ensure

adequate freeze protection.

When starting and  stopping an engine many

times without being operated in order to warm  up

completely, the carbon deposits become thicker.

This starting and stopping can cause the following

problems:

Engine Block Heaters

•  Free operation of the valves is prevented.

•  Valves become stuck.

Engine block heaters  (if equipped) heat  the

engine jacket water that surrounds the combustion

chambers. This heat provides the following functions:

•  Pushrods may become bent.

•  Startability is improved.

•  Warm up time is reduced.

•  Other damage to valve train  components can

result.

An electric block heater can be activated once the

engine is stopped. A block heater can be 110 V dc or

240 V dc. The output can be 750/1000W. Consult

your Perkins dealer or your Perkins distributor  for

more information.

For this reason,  when the engine is  started,

the engine must  be operated until the coolant

temperature is 80° C (176° F)  minimum. Carbon

deposits on the valve stems will be kept at a minimum

and the free operation of the valves and the valve

components will be maintained.

Idling the Engine

The engine must be thoroughly warmed  in order

to keep other engine parts in better condition. The

service life of the engine will be generally extended.

Lubrication will be improved. There will be less acid

and less sludge in the oil. This condition will provide

longer service life for the engine bearings, the piston

rings, and other parts. However, limit unnecessary

idle time to 10 minutes in order to reduce wear and

unnecessary fuel consumption.

When idling after the  engine is started in cold

weather, increase the engine rpm from 1000 to 1200

rpm. This idling will warm up the engine more quickly.

Maintaining an elevated low idle speed for extended

periods will be easier with the installation of a hand

throttle. The engine should not be “raced” in order to

speed up the warm-up process.

While the engine is idling, the application of a light

load (parasitic load) will  assist in achieving the

minimum operating temperature. The  minimum

operating temperature is 80° C (176° F).

The Water Temperature Regulator and

Insulated Heater Lines

The engine is equipped with a water temperature

regulator. When the engine coolant  is below the

correct operating temperature, jacket water circulates

through the engine cylinder  block and into the

engine cylinder head. The coolant then returns to the

cylinder block via an internal passage that bypasses

the valve of the coolant temperature regulator. This

ensures that coolant flows around the engine under

cold operating conditions. The water temperature

regulator begins to open when  the engine jacket

water has reached the correct minimum operating

temperature. As the jacket water coolant temperature

rises above the minimum operating temperature, the

water temperature regulator opens further allowing

more coolant through the radiator to dissipate excess

heat.

Recommendations for Coolant

Warm Up

Warm up an engine that has cooled below normal

operating temperatures due to inactivity. This warm

-up should be  performed before the engine is

returned to full operation. During operation in very

cold temperature conditions, damage to  engine

valve mechanisms can result from engine operation

for short intervals. This damage can happen if the

engine is started and the engine is stopped many

times without being operated in order to  warm up

completely.

When the engine is operated below normal operating

temperatures, fuel and oil are not completely burned

in the combustion chamber. This fuel and oil causes

soft carbon deposits to form  on the valve stems.

Generally, the deposits do not cause problems and

the deposits are burned  off during operation at

normal engine operating temperatures.

The progressive opening of the water temperature

regulator operates the progressive closing of  the

bypass passage between the cylinder block  and

head. This action ensures maximum coolant flow

to the radiator in order to achieve  maximum heat

dissipation.

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Operation Section

Cold Weather Operation

Note: Do not restrict  the air flow. Restriction of

the air flow can damage the fuel  system. Perkins

discourages the use  of all air flow  restriction

devices such as radiator shutters. Restriction of the

air flow can result in  the following: high exhaust

temperatures, power loss, excessive fan usage, and

reduction in fuel economy.

i02685960

Fuel and the Effect from Cold

Weather

Note: Only use grades of fuel that are recommended

by Perkins. Refer to this Operation and Maintenance

Manual, “Fluid Recommendations”.

A cab heater is beneficial in very cold weather. The

feed from the engine and the return lines from the

cab should be insulated in order to reduce heat loss

to the outside air.

The following components provide  a means of

minimizing problems in cold weather:

Recommendation for Crankcase Breather

Protection

•  Glow plugs (if equipped)

•  Engine coolant heaters, which may be an OEM

option

Crankcase ventilation gases contain a large quantity

of water vapor. This  water vapor can freeze in

cold ambient conditions and can plug or  damage

the crankcase ventilation system. If the engine  is

operated in temperatures below −25° C (−13°  F),

measures must be taken to prevent freezing  and

plugging of the breather system. Insulated hoses and

a heated canister assembly should be installed.

•  Fuel heaters, which may be an OEM option

•  Fuel line insulation, which may be an OEM option

The cloud point is a temperature  that allows wax

crystals to form in the fuel. These crystals can cause

the fuel filters to plug.

Consult with your Perkins dealer or  your Perkins

distributer for  the recommended breather

components for operation  from −25° to -40°C

(−13° to -72.°F).

The pour point is the temperature when diesel fuel

will thicken. The diesel fuel becomes more resistant

to flow through fuel lines, fuel filters,and fuel pumps.

Be aware of  these facts when  diesel fuel is

purchased. Consider the average  ambient air

temperature for the engine's application. Engines that

are fueled in one climate may not operate well if the

engines are moved to another climate. Problems can

result due to changes in temperature.

Before troubleshooting for low power  or for poor

performance in the winter, check the fuel for waxing.

Low temperature fuels may be available for engine

operation at temperatures below 0 °C (32 °F). These

fuels limit the formation of  wax in the fuel at low

temperatures.

For more information on cold weather operation, refer

to the Operation and Maintenance Manual, “Cold

Weather Operation and Fuel Related Components in

Cold Weather”.

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SEBU8605-01

Operation Section

Cold Weather Operation

i02323237

Fuel Related Components in

Cold Weather

Fuel Tanks

Condensation can form in partially filled fuel tanks.

Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for draining

water and sediment from the bottom of the tanks.

Some fuel tanks use supply pipes that allow water

and sediment to settle below  the end of the fuel

supply pipe.

Some fuel tanks use  supply lines that take fuel

directly from the bottom of the tank. If the engine is

equipped with this system, regular maintenance of

the fuel system filter is important.

Drain the water and sediment from any fuel storage

tank at the following  intervals: weekly, service

intervals, and refueling of the fuel tank. This will help

prevent water and/or sediment from being pumped

from the fuel storage tank and into the engine fuel

tank.

Fuel Filters

A primary fuel filter is  installed between the fuel

tank and the engine fuel  inlet. After you change

the fuel filter, always prime the fuel system in order

to remove air bubbles from the fuel system. Refer

to the Operation and Maintenance Manual  in the

Maintenance Section for more information on priming

the fuel system.

The location of a primary fuel filter is important in cold

weather operation. The primary fuel filter and the fuel

supply line are the most common components that

are affected by cold fuel.

Fuel Heaters

Note: The OEM may equip the application with fuel

heaters. If this is the case, the temperature of the fuel

must not exceed 73 °C (163 °F) at the fuel transfer

pump.

For more information about fuel heaters (if equipped),

refer to the OEM information.

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63

Maintenance Section

Refill Capacities

Maintenance Section

Refill Capacities

i04262329

Refill Capacities

Lubrication System

The refill capacities  for the engine crankcase

reflect the approximate capacity of the crankcase

or sump plus standard oil filters. Auxiliary  oil filter

systems will require additional oil. Refer to the OEM

specifications for the capacity of the auxiliary oil filter.

Refer to the Operation and Maintenance Manual,

“Maintenance Section” for more  information on

Lubricant Specifications.

Table 6

Engine

Refill Capacities

Minimum

(1)

Maximum

(2)

Compartment or System

6 L (1.32

Imp gal)

14 L (3.1

Imp gal)

Crankcase Oil Sump

(1)  The minimum value is the  approximate capacity for the

crankcase oil sump (aluminum) which includes the standard

factory installed oil filters. Engines with auxiliary oil filters will

require additional oil. Refer to the OEM specifications  for the

capacity of the auxiliary oil filter. The design of the oil pan can

change the oil capacity of the oil pan.

(2)  Approximate capacity of the largest crankcase oil sump. Refer

to OEM for more information.

Cooling System

Refer to the OEM specifications  for the External

System capacity. This capacity  information will

be needed in order  to determine the amount of

coolant/antifreeze that is required  for the Total

Cooling System.

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SEBU8605-01

Maintenance Section

Refill Capacities

Table 7

Engine

Refill  Capacities

Compartment or System

Engine Only

Liters

Engine

Engine

TA

(1)

TTA

(2)

9 L (1.97 Imp gal)

9.4 L (2.07 Imp gal)

External System Per OEM

(3)

(1)  Single Turbocharger

(2)  Series Turbochargers

(3)  The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the

OEM specifications. Enter the value for the capacity  of the External System in this row.

These failures can be avoided with correct cooling

i04229329

system maintenance. Cooling system maintenance is

as important as maintenance of the fuel system and

Fluid Recommendations

the lubrication system. Quality of the coolant is as

important as the quality of the fuel and the lubricating

oil.

General Coolant Information

Coolant is normally composed of three elements:

Water, additives, and glycol.

NOTICE

Never add coolant  to an overheated engine.  Engine

damage could result. Allow the engine to cool first.

Water

Water is used in  the cooling system in order to

transfer heat.

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 temper-

ature or drained completely to prevent damage.

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.

NOTICE

Frequently check the specific gravity of the coolant for

proper freeze protection or for anti-boil protection.

If distilled water or deionized water is not available,

use water with the properties that are listed in Table 8.

Clean the cooling system for the following reasons:

•  Contamination of the cooling system

•  Overheating of the engine

Table 8

Acceptable Water

Property

Chloride (Cl)

Sulfate (SO4)

Total Hardness

Total Solids

Acidity

Maximum Limit

40 mg/L

•  Foaming of the coolant

100 mg/L

170 mg/L

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 prob-

lems can develop  without water temperature regula-

tors.

340 mg/L

pH of  5.5 to 9.0

For a water analysis, consult one of  the following

sources:

•  Local water utility company

•  Agricultural agent

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.

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SEBU8605-01

65

Maintenance Section

Refill Capacities

•  Independent laboratory

Table 9

Ethylene Glycol

Additives

Concentration

Freeze Protection

−36 °C  (−33 °F)

−51 °C  (−60 °F)

Additives help to protect  the metal surfaces of

the cooling system. A lack of coolant  additives or

insufficient amounts of additives enable the following

conditions to occur:

50 Percent

60 Percent

NOTICE

•  Corrosion

Do not use propylene glycol in concentrations that ex-

ceed 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.

•  Formation of mineral deposits

•  Rust

•  Scale

Table 10

•  Foaming of the coolant

Propylene Glycol

Concentration

Freeze Protection

Many additives are depleted during engine operation.

These additives must be replaced periodically.

50 Percent

−29 °C  (−20 °F)

Additives must be added at the correct concentration.

Over concentration of additives  can cause the

inhibitors to drop out-of-solution. The deposits can

enable the following problems to occur:

To check the concentration of glycol in the coolant,

measure the specific gravity of the coolant.

Coolant Recommendations

•  Formation of gel compounds

•  ELC____________________________Extended Life Coolant

•  SCA___________________Supplement Coolant Additive

•  Reduction of heat transfer

•  Leakage of the water pump seal

•  Plugging of radiators, coolers, and small passages

•  ASTM__________________________________________American

Society for Testing and Materials

The following two coolants are used in Perkins diesel

engines:

Glycol

Glycol in the coolant helps  to provide protection

against the following conditions:

Preferred  – Perkins ELC

Acceptable  – A commercial heavy-duty antifreeze

that meets “ASTM D6210 ” specifications

•  Boiling

•  Freezing

NOTICE

•  Cavitation of the water pump

The 1200 series industrial engines must  be oper-

ated with a  1:1 mixture of water  and glycol. This

concentration allows the NOx reduction system to

operate correctly at high ambient temperatures.

For optimum performance, Perkins recommends a

1:1 mixture of a water/glycol solution.

Note: Use a mixture that  will provide protection

against the lowest ambient temperature.

NOTICE

Do not use  a commercial coolant/antifreeze that  on-

ly meets the ASTM D3306 specification.  This type of

coolant/antifreeze is made for  light automotive appli-

cations.

Note: 100 percent  pure glycol will freeze at  a

temperature of −13 °C (8.6 °F).

Most conventional antifreezes 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. Refer

to Table 9 and refer to table 10.

Perkins recommends a 1:1 mixture of  water and

glycol. This mixture of water and glycol will provide

optimum heavy-duty performance as an antifreeze.

This ratio may be increased to 1:2 water to glycol if

extra freezing protection is required.

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SEBU8605-01

Maintenance Section

Refill Capacities

ELC Cooling System Maintenance

A mixture of SCA inhibitor and water is acceptable but

will not give the same level of corrosion, boiling and,

freezing protection as ELC. Perkins recommends a 6

percent to 8 percent concentration of SCA in those

cooling systems. Distilled water or deionized water

is preferred. Water which has the  recommended

properties may be used.

Correct additions to the Extended Life

Coolant

NOTICE

Use only Perkins  products for pre-mixed  or concen-

trated coolants.

Table 11

Coolant Service  Life

Mixing Extended Life Coolant with other products re-

duces the Extended Life Coolant service life. Failure to

follow the recommendations can reduce cooling  sys-

tem components life unless appropriate corrective ac-

tion is performed.

Coolant Type

Service Life

(1)

6,000 Service Hours  or

Three Years

Perkins ELC

Commercial Heavy-Duty

Antifreeze that meets

“ASTM D6210”

3000 Service Hours  or

Two Year

In order to maintain the correct balance  between

the antifreeze and the additives, you must maintain

the recommended concentration of ELC. Lowering

the proportion of antifreeze 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.

Commercial SCA inhibitor

and Water

3000 Service Hours  or

One Year

(1)  Use the interval that occurs first. The cooling  system must

also be flushed out at this time.

ELC

NOTICE

Do not use a conventional coolant to top-off a cooling

system that is filled with Extended Life Coolant (ELC).

Perkins provides ELC  for use in the following

applications:

•  Heavy-duty spark ignited gas engines

•  Heavy-duty diesel engines

•  Automotive applications

Do not  use  standard supplemental  coolant additive

(SCA).

When using Perkins ELC, do not use standard SCA's

or SCA filters.

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 Cooling System Cleaning

Note: If the cooling system is already using  ELC,

cleaning agents are not  required to be used at

the specified coolant change  interval. Cleaning

agents are only required if  the system has been

contaminated by the addition of some other type of

coolant or by cooling system damage.

ELC is available in a premixed cooling solution with

distilled water. ELC is a 1:1 mixture. The Premixed

ELC provides freeze protection to −36 °C (−33 °F).

The Premixed ELC is recommended for the initial

fill of the cooling system. The Premixed ELC is also

recommended for topping off the cooling system.

Clean water is the only cleaning agent that is required

when ELC is drained from the cooling system.

Before the cooling system is filled, the heater control

(if equipped) must be set to the hot position. Refer

to the OEM in order to set the heater control. After

the cooling system is drained and the cooling system

is refilled, 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 fill the system to the

specified level.

Containers of several sizes are available. Consult

your Perkins distributor for the part numbers.

Changing to Perkins ELC

To change from heavy-duty antifreeze to the Perkins

ELC, perform the following steps:

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SEBU8605-01

67

Maintenance Section

Refill Capacities

ELC Cooling System Contamination

NOTICE

Care  must  be  taken  to  ensure  that  all  fluids  are

contained  during  performance of  inspection,  main-

tenance,  testing,  adjusting   and  the  repair  of   the

product. Be prepared to collect the  fluid with suitable

containers before  opening any  compartment or  dis-

assembling any component containing fluids.

NOTICE

Mixing ELC with other products reduces the effective-

ness of  the ELC and  shortens the  ELC service life.

Use only  Perkins Products  for premixed or  concen-

trate coolants.  Failure to follow  these recommenda-

tions can result  in shortened cooling system compo-

nent life.

Dispose of all fluids according to local regulations and

mandates.

ELC cooling systems can withstand contamination to

a maximum of 10 percent of conventional heavy-duty

antifreeze or SCA. If the contamination exceeds 10

percent of the total system capacity, perform ONE of

the following procedures:

1.  Drain the coolant into a suitable container.

2.  Dispose of the coolant  according to local

regulations.

•  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.

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.

•  Drain a portion of the cooling system into a suitable

container according to local regulations. Then,

fill the cooling system with premixed ELC.  This

procedure should lower the contamination to less

than 10 percent.

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 66°C (120° to 150°F).

•  Maintain the system as a conventional Heavy-Duty

Coolant. Treat the system with an SCA. Change

the coolant at the interval that is recommended for

the conventional Heavy-Duty Coolant.

NOTICE

Incorrect or incomplete flushing of the cooling system

can result in damage to copper and other metal com-

ponents.

Commercial Heavy-Duty Antifreeze and

SCA

To avoid damage to the cooling system, make sure to

completely flush the cooling system with  clear water.

Continue to flush the system until  all the signs of the

cleaning agent are gone.

NOTICE

Commercial   Heavy-Duty  Coolant   which   contains

Amine as part of the corrosion protection system must

not be used.

7.  Drain the cooling system into a suitable container

and flush the cooling system with clean water.

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 prob-

lems can develop  without water temperature regula-

tors.

Note: The cooling system cleaner must be thoroughly

flushed 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 repeat steps  7 until the

system is completely clean.

Check the antifreeze  (glycol concentration) in

order to ensure adequate protection against boiling

or freezing. Perkins recommends  the use of a

refractometer for checking the glycol concentration.

A hydrometer should not be used.

9.  Fill the cooling system with the Perkins Premixed

ELC.

Perkins engine cooling systems should be tested at

500 hour intervals for the concentration of SCA.

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SEBU8605-01

Maintenance Section

Refill Capacities

Additions of SCA are based on the results of the test.

An SCA that is liquid may be needed  at 500 hour

intervals.

Table 15 is an example for using the equation that

is in Table 14.

Table 15

Adding the SCA to Heavy-Duty Coolant

at the Initial Fill

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant For Maintenance

Total Volume

of the Cooling

System (V)

Multiplication

Factor

Amount of

SCA that  is

Required (X)

Use the equation that is in Table 12 to determine the

amount of SCA that is required when  the cooling

system is initially filled.

15 L (4 US gal)

× 0.014

0.2 L (7 oz)

Table 12

Cleaning the System  of Heavy-Duty

Antifreeze

Equation For Adding The SCA To The Heavy-Duty

Coolant At  The Initial Fill

V ×  0.045 =  X

•  Clean the cooling system after used  coolant is

drained or before the cooling system is filled with

new coolant.

V is the total volume of the cooling system.

X is the amount of SCA that is required.

•  Clean the cooling system whenever the coolant is

contaminated or whenever the coolant is foaming.

Table 13 is an example for using the equation that

is in Table 12.

Table 13

i04156282

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant At The Initial  Fill

Fluid Recommendations

Total Volume

of the Cooling

System (V)

Multiplication

Factor

Amount of

SCA that  is

Required (X)

General Lubricant Information

15 L (4 US gal)

× 0.045

0.7 L (24 oz)

Because of government regulations regarding the

certification of exhaust emissions from the engine,

the lubricant recommendations must be followed.

Adding The SCA to  The Heavy-Duty

Coolant For Maintenance

•  API_____________________American Petroleum Institute

Heavy-duty antifreeze of all types REQUIRE periodic

additions of an SCA.

•

SAE___________________________________________Society Of

Automotive Engineers Inc.

Test the antifreeze periodically for the concentration

of SCA. For the  interval, refer to the Operation

and Maintenance Manual, “Maintenance Interval

Schedule” (Maintenance Section). Cooling System

Supplemental Coolant Additive (SCA) Test/Add.

•

ACEA__________________________________Association des

Constructers European Automobiles.

•  ECF-3_______________________Engine Crankcase Fluid

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.

Licensing

The Engine Oil Licensing and Certification System

by the American Petroleum  Institute (API) and

the Association des  Constructers European

Automobilesand (ACRA) 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.

Use the equation that is in Table 14 to determine the

amount of SCA that is required, if necessary:

Table 14

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.

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SEBU8605-01

69

Maintenance Section

Refill Capacities

The chemical limits  were developed in order

to maintain the  expected life of  the engine

aftertreatment system. The performance  of the

engine aftertreatment system can  be adversely

affected if oil that is not specified in table 16 is used.

The life of your Aftertreatment system is defined by

the accumulation of ash on the surface of the filter.

Ash is the inert part of the  particulate matter. The

system is designed in order to collect this particulate

matter. There is a very small percentage of particulate

matter that is left behind as the soot is burnt.  This

matter will eventually block the filter, causing loss

of performance and increased fuel consumption.

Most of the ash comes from the engine oil which is

gradually consumed during normal operation. This

ash is passes through the  exhaust. To meet the

designed life of the product, the use of the appropriate

engine oil is essential. The oil specification that is

listed in table 16 has low ash content.

g01987816

Illustration 42

Typical API symbol