Perkins 1206J-E70TA and 1206J-E70TTA Industrial Engines. Operation Manual (2021)

M0082024-03

107

Maintenance Section

Aftercooler Core - Clean/Test

i01807350

i02322311

Aftercooler Core - Clean/Test

Alternator - Inspect

(Air-To-Air Aftercooler)

Perkins recommends a scheduled inspection of the

alternator. Inspect the alternator for loose

The air-to-air aftercooler is OEM installed in many

connections and correct battery charging. Check the

applications. Please refer to the OEM specifications

ammeter (if equipped) during engine operation in

for information that is related to the aftercooler.

order to ensure correct battery performance and/or

correct performance of the electrical system. Make

i02322295

repairs, as required.

Check the alternator and the battery charger for

Aftercooler Core - Inspect

correct operation. If the batteries are correctly

charged, the ammeter reading should be very near

zero. All batteries should be kept charged. The

Note: Adjust the frequency of cleaning according to

batteries should be kept warm because temperature

the effects of the operating environment.

affects the cranking power. If the battery is too cold,

the battery will not crank the engine. When the

Inspect the aftercooler for these items: damaged fins,

engine is not run for long periods of time or if the

corrosion, dirt, grease, insects, leaves, oil and other

engine is run for short periods, the batteries may not

debris. Clean the aftercooler, if necessary.

fully charge. A battery with a low charge will freeze

more easily than a battery with a full charge.

For air-to-air aftercoolers, use the same methods that

are used for cleaning radiators.

i02680137

Alternator and Fan Belts -

Personal injury can result from air pressure.

Replace

Personal injury can result without following prop-

er procedure. When using pressure air, wear a

Refer to Disassembly and Assembly Manual , “

protective face shield and protective clothing.

Alternator Belt - Remove and Install”.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

i05425759

Battery - Replace

After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal

of debris and drying of the core. Stop the engine. Use

a light bulb behind the core in order to inspect the

core for cleanliness. Repeat the cleaning, if

necessary.

Batteries give off combustible gases which can

explode. A spark can cause the combustible

Inspect the fins for damage. Bent fins may be opened

gases to ignite. This can result in severe personal

with a “comb”.

injury or death.

Note: If parts of the aftercooler system are repaired

Ensure proper ventilation for batteries that are in

or replaced, a leak test is highly recommended.

an enclosure. Follow the proper procedures in or-

der to help prevent electrical arcs and/or sparks

Inspect these items for good condition: Welds,

near batteries. Do not smoke when batteries are

mounting brackets, air lines, connections, clamps

serviced.

and seals. Make repairs, if necessary.

108

M0082024-03

Maintenance Section

Battery Electrolyte Level - Check

The battery cables or the batteries should not be

All lead-acid batteries contain sulfuric acid which

removed with the battery cover in place. The bat-

can burn the skin and clothing. Always wear a

tery cover should be removed before any servic-

face shield and protective clothing when working

ing is attempted.

on or near batteries.

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion

1. Remove the filler caps. Maintain the electrolyte

resulting in personal injury.

level to the “FULL” mark on the battery.

If the addition of water is necessary, use distilled

1. Switch the engine to the OFF position. Remove all

water. If distilled water is not available use clean

electrical loads.

water that is low in minerals. Do not use artificially

softened water.

Note: After the engine has stopped, allow 2 minutes

in order for the diesel exhaust fluid lines to be purged

2. Check the condition of the electrolyte with a

before disconnecting the power.

suitable battery tester.

2. Turn off any battery chargers. Disconnect any

3. Install the caps.

battery chargers.

4. Keep the batteries clean.

3. Ensure that the battery disconnect switch is in the

Clean the battery case with one of the following

OFF position.

cleaning solutions:

4. Disconnect the NEGATIVE “-” cable from the

• Use a solution of 0.1 kg (0.2 lb) baking soda

NEGATIVE “-” battery terminal.

and 1 L (1 qt) of clean water.

5. Disconnect the POSITIVE “+” cable from the

POSITIVE “+” battery terminal.

• Use a solution of ammonium hydroxide.

Note: Always recycle a battery. Never discard a

Thoroughly rinse the battery case with clean

battery. Dispose of used batteries to an appropriate

water.

recycling facility.

i05424317

6. Remove the used battery.

Battery or Battery Cable -

7. Install the new battery.

Disconnect

Note: Before the cables are connected, ensure that

the battery disconnect switch is in the OFF position.

8. Connect the POSITIVE “+” cable to the POSITIVE

“+” battery terminal.

The battery cables or the batteries should not be

9. Connect the NEGATIVE “-” cable to the

removed with the battery cover in place. The bat-

NEGATIVE “-” battery terminal.

tery cover should be removed before any servic-

ing is attempted.

10. Turn the battery disconnect switch to the ON

position.

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion

i02747977

resulting in personal injury.

Battery Electrolyte Level -

1. Turn the start switch to the OFF position. Turn the

Check

ignition switch (if equipped) to the OFF position

and remove the key and all electrical loads.

Note: After the engine has stopped, allow 2 minutes

When the engine is not run for long periods of time or

when the engine is run for short periods, the batteries

in order for the diesel exhaust fluid lines to be purged

may not fully recharge. Ensure a full charge in order

before disconnecting the power.

to help prevent the battery from freezing. If batteries

are correctly charged, the ammeter reading should

be very near zero, when the engine is in operation.

M0082024-03

109

Maintenance Section

Belt - Inspect

2. Disconnect the negative battery terminal. Ensure

• Inspect the belt for cracks, splits, glazing, grease,

that the cable cannot contact the terminal. When

displacement of the cord and evidence of fluid

four 12 V batteries are involved, 2 negative

contamination.

connections must be disconnected.

The belt must be replaced if the following conditions

are present.

3. Remove the positive connection.

4. Clean all disconnected connection and battery

• The belt has a crack in more than one rib.

terminals.

• More than one section of the belt is displaced in

5. Use a fine grade of sandpaper to clean the

one rib of a maximum length of 50.8 mm (2 inch).

terminals and the cable clamps. Clean the items

To replace the belt, refer to Disassembly and

until the surfaces are bright or shiny. DO NOT

Assembly, “Alternator Belt - Remove and Install”. If

remove material excessively. Excessive removal

necessary, replace the belt tensioner. Refer to

of material can cause the clamps to fit incorrectly.

Disassembly and Assembly, “Alternator Belt -

Coat the clamps and the terminals with a suitable

Remove and Install” for the correct procedure.

silicone lubricant or petroleum jelly.

i04907925

6. Tape the cable connections in order to help

prevent accidental starting.

Belt Tensioner - Check

7. Proceed with necessary system repairs.

8. In order to connect the battery, connect the

positive connection before the negative connector.

i04907868

Belt - Inspect

Illustration 63

g03074016

Typical example

Remove the belt. Refer to Disassembly and

Assembly, “Alternator Belt - Remove and Install”.

Ensure that the belt tensioner is securely installed.

Visually inspect the belt tensioner (1) for damage.

Check that the pulley on the tensioner rotates freely

Illustration 62

g03073936

and that the bearing is not loose. Some engines have

Typical example

an idler pulley (2). Ensure that the idler pulley is

securely installed. Visually inspect the idler pulley for

To maximize the engine performance, inspect the

damage. Ensure that the idler pulley can rotate freely

belt (1) for wear and for cracking. Replace the belt if

and that the bearing is not loose. If necessary,

the belt is worn or damaged.

replace damaged components.

Install the belt. Refer to Disassembly and Assembly,

“Alternator Belt - Remove and Install”.

110

M0082024-03

Maintenance Section

Coolant (Commercial Heavy-Duty) - Change

i07679030

Coolant (Commercial Heavy-

Duty) - Change

Clean the cooling system and flush the cooling

system before the recommended maintenance

interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and the

coolant is contaminated.

• The fuel has entered the cooling system and the

coolant is contaminated.

NOTICE

When any servicing or repair of the engine cooling

Illustration 64

g03461657

system is performed, the procedure must be per-

formed with the engine on level ground. Level ground

will allow you to check accurately the coolant level.

This procedure will also help in avoiding the risk of in-

troducing an air lock into the coolant system.

Note: Inspect the water pump and the water

temperature regulator after the cooling system has

been drained. This inspection is a good opportunity

to replace the water pump, the water temperature

regulator, and the hoses, if necessary.

Drain

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

pressure.

Illustration 65

g02350785

1. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly to

2. Remove connection hose (1) on the engine. Also

relieve any pressure. Remove the cooling system

remove the drain plug (2). Open the drain cock or

filler cap.

remove the drain plug on the radiator.

Note: Refer to Operation and Maintenance Manual,

Allow the coolant to drain into a suitable container.

“General Hazard Information” for information on

3. Properly dispose of the drained material. Obey

Containing Fluid Spillage.

local regulations for the disposal of the material.

M0082024-03

111

Maintenance Section

Coolant (Commercial Heavy-Duty) - Change

Alternative Drain Plug

NOTICE

Do not fill the cooling system faster than 10 L

The cylinder coolant can be drained from the plug

(2.64 US gal) per minute to avoid air locks.

below the oil cooler. Refer to illustration 66 . If the

alternative drain plug (3) is removed, the O ring seal

Cooling system air locks may result in engine

must be replaced. Tighten the drain plug to a torque

damage.

of 35 N·m (25 lb ft).

3. Fill the cooling system with clean water and install

the cooling system filler cap.

4. Start and run the engine at low idle for a minimum

of 30 minutes. The coolant temperature should be

at least 85° C (185° F).

NOTICE

Improper or incomplete rinsing of the cooling system

can result in damage to copper and other metal

components.

To avoid damage to the cooling system, make sure to

completely flush the cooling system with clear water.

Continue to flush the system until all signs of the

cleaning agent are gone.

5. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly to

relieve any pressure. Remove the cooling system

filler cap. Remove the connection hose or remove

Illustration 66

g03081697

the cooling system drain plugs. Allow the water to

drain. Flush the cooling system with clean water.

Flush

Install the connection hose.

6. The drain plug O rings on the engine block must be

NOTICE

Most commercial cooling system cleaning agents are

replaced. Clean the drain plugs and install new O

corrosive and their use is not recommended by Per-

ring seal. Install the drain plugs and tighten to a

kins. If commercial cooling system cleaning agents

torque of 35 N·m (25 lb ft).

have to be used, then the cleaning agents should not

be left in the system any longer then recommended

Fill

by manufacturers and engine temperature should not

be elevated above 30 degrees C.

NOTICE

The system must be thoroughly flushed with clean

Do not fill the cooling system faster than 10 L

water after use of cleaning agents.

(2.64 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine

NOTICE

damage.

Cleaning agents for marine or industrial cooling sys-

tems must not be used as they are very aggressive

and will damage cooling system components.

1. Fill the cooling system with the coolant/antifreeze.

Refer to this Operation and Maintenance Manual,

“Refill Capacities and Recommendations” topic

1. Flush the cooling system with clean water and a

(Maintenance Section) for more information on

suitable cleaning agent to remove any debris.

cooling system specifications.

Refer to your Perkins dealer or distributor for

suitable cleaning agents.

2. Start and run the engine at low idle. Increase the

engine rpm to high idle. Operate the engine to

2. Install connection hose. Clean the drain plugs.

open the engine thermostat. This operation will

Install the drain plugs. Tighten drain plug securely.

allow any air in the system to be purged. Decrease

the engine speed to low idle. Stop the engine.

112

M0082024-03

Maintenance Section

Coolant (ELC) - Change

3. Maintain the coolant level at the maximum mark

Drain

that is correct for your application.

4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If

Pressurized System: Hot coolant can cause seri-

the gasket that is on the cooling system filler cap is

ous burns. To open the cooling system filler cap,

damaged, discard the old cooling system filler cap

stop the engine and wait until the cooling system

and install a new cooling system filler cap. If the

components are cool. Loosen the cooling system

gasket that is on the cooling system filler cap is not

pressure cap slowly in order to relieve the

pressure.

damaged, perform a pressure test. If the cooling

system filler cap does not retain the correct

pressure, install a new cooling system filler cap.

1. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly to

5. Start the engine. Inspect the cooling system for

relieve any pressure. Remove the cooling system

leaks and for the correct operating temperature.

filler cap.

i07682735

Coolant (ELC) - Change

Clean the cooling system and flush the cooling

system before the recommended maintenance

interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and the

coolant is contaminated.

• The fuel has entered the cooling system and the

coolant is contaminated.

Note: When the cooling system is cleaned, only

clean water is needed when the ELC is drained and

replaced.

Note: Inspect the water pump and the water

temperature regulator after the cooling system has

been drained. Replace the water pump, the water

temperature regulator, and the hoses, if necessary.

NOTICE

Service or repair of the engine cooling system must

be performed on level ground. The engine must be

level to check the coolant level. The engine must be

level to avoid the risk of introducing an air lock into

the coolant system.

M0082024-03

113

Maintenance Section

Coolant (ELC) - Change

For information regarding the disposal and the

recycling of used coolant, consult your Perkins dealer

or Perkins distributor.

Flush

1. Flush the cooling system with clean water to

remove any debris.

2. Install the connection hose. Clean the drain plugs

and install the drain plugs. Tighten the drain plugs

securely.

NOTICE

Do not fill the cooling system faster than 5 L

(1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine

damage.

3. Fill the cooling system with clean water. Install the

cooling system filler cap.

Illustration 67

g03461657

4. Start and run the engine at low idle until the

temperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly to

relieve any pressure. Remove the cooling system

filler cap. Remove the connection hose and

remove the cooling system drain plugs. Allow the

water to drain. Flush the cooling system with clean

water. Install the connection hose.

6. The drain plug O rings on the engine block must be

replaced. Clean the drain plugs and install new O

ring seal. Install the drain plugs and tighten to a

torque of 35 N·m (25 lb ft).

Fill

NOTICE

Do not fill the cooling system faster than 5 L

(1.3 US gal) per minute to avoid air locks.

Illustration 68

g02350785

Cooling system air locks may result in engine

damage.

2. Remove connection hose (1) on the engine. Also

remove the drain plug (2). Open the drain cock or

1. Fill the cooling system with Extended Life Coolant

remove the drain plug on the radiator.

(ELC). Refer to this Operation and Maintenance

Allow the coolant to drain.

Manual, “Refill Capacities” topic (Maintenance

Section) for more information on cooling system

specifications. Do not install the cooling system

filler cap.

114

M0082024-03

Maintenance Section

Coolant - Change

2. Start and run the engine at low idle. Increase the

• The fuel has entered the cooling system and the

engine rpm to high idle. Operate the engine to

coolant is contaminated.

open the engine thermostat. An open thermostat

will allow any air in the system to be purged.

NOTICE

Decrease the engine speed to low idle. Stop the

When any servicing or repair of the engine cooling

system is performed, the procedure must be per-

engine.

formed with the engine on level ground. Level ground

3. Maintain the coolant level at the maximum mark

will allow you to check accurately the coolant level.

This procedure will also help in avoiding the risk of in-

that is correct for your application.

troducing an air lock into the coolant system.

4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If

Note: Inspect the water pump and the water

the gasket that is on the cooling system filler cap is

temperature regulator after the cooling system has

damaged, discard the old cooling system filler cap

been drained. This inspection is a good opportunity

and install a new cooling system filler cap. If the

to replace the water pump, the water temperature

gasket that is on the cooling system filler cap is not

regulator, and the hoses, if necessary.

damaged, pressure test the cooling system filler

cap. The correct pressure for the cooling system

Drain

filler cap is stamped on the face of the cooling

system filler cap. If the cooling system filler cap

does not retain the correct pressure, install a new

cooling system filler cap.

Pressurized System: Hot coolant can cause seri-

5. Start the engine. Inspect the cooling system for

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

leaks and for proper operating temperature.

components are cool. Loosen the cooling system

pressure cap slowly in order to relieve the

i07711032

pressure.

Coolant - Change

1. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly to

relieve any pressure. Remove the cooling system

NOTICE

filler cap.

Keep all parts clean from contaminants.

Note: Refer to Operation and Maintenance Manual,

Contaminants may cause rapid wear and shortened

“General Hazard Information” for information on

component life.

Containing Fluid Spillage.

NOTICE

Care must be taken to ensure that fluids are con-

tained during performance of inspection, mainte-

nance, testing, adjusting and repair of the product.

Be prepared to collect the fluid with suitable contain-

ers before opening any compartment or disassem-

bling any component containing fluids.

Dispose of all fluids according to local regulations

and mandates.

Clean the cooling system and flush the cooling

system before the recommended maintenance

interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and the

coolant is contaminated.

M0082024-03

115

Maintenance Section

Coolant - Change

Alternative Drain Plug

The cylinder coolant can be drained from the plug

below the oil cooler. Refer to illustration 71 . If the

alternative drain plug (3) is removed, the O ring seal

must be replaced. Tighten the drain plug to a torque

of 35 N·m (25 lb ft).

Illustration 69

g03461657

Illustration 71

g03081697

Flush

NOTICE

Most commercial cooling system cleaning agents are

corrosive and their use is not recommended by Per-

kins. If commercial cooling system cleaning agents

have to be used, then the cleaning agents should not

be left in the system any longer then recommended

by manufacturers and engine temperature should not

be elevated above 30 degrees C.

The system must be thoroughly flushed with clean

water after use of cleaning agents.

Illustration 70

g02350785

NOTICE

Cleaning agents for marine or industrial cooling sys-

tems must not be used as they are very aggressive

2. Remove connection hose (1) on the engine. Also

and will damage cooling system components.

remove the drain plug (2). Open the drain cock or

remove the drain plug on the radiator.

1. Flush the cooling system with clean water and a

Allow the coolant to drain into a suitable container.

suitable cleaning agent to remove any debris.

Refer to your Perkins dealer or distributor for

3. Properly dispose of the drained material. Obey

local regulations for the disposal of the material.

suitable cleaning agents.

2. Install connection hose. Clean the drain plugs.

Install the drain plugs. Tighten drain plug securely.

116

M0082024-03

Maintenance Section

Coolant Level - Check

3. Maintain the coolant level at the maximum mark

NOTICE

that is correct for your application.

Do not fill the cooling system faster than 10 L

(2.64 US gal) per minute to avoid air locks.

4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If

Cooling system air locks may result in engine

damage.

the gasket that is on the cooling system filler cap is

damaged, discard the old cooling system filler cap

and install a new cooling system filler cap. If the

3. Fill the cooling system with clean water and install

gasket that is on the cooling system filler cap is not

the cooling system filler cap.

damaged, perform a pressure test. If the cooling

4. Start and run the engine at low idle for a minimum

system filler cap does not retain the correct

of 30 minutes. The coolant temperature should be

pressure, install a new cooling system filler cap.

at least 85° C (185° F).

5. Start the engine. Inspect the cooling system for

leaks and for the correct operating temperature.

NOTICE

Improper or incomplete rinsing of the cooling system

can result in damage to copper and other metal

i07676461

components.

Coolant Level - Check

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 signs of the

cleaning agent are gone.

Pressurized System: Hot coolant can cause seri-

5. Stop the engine and allow the engine to cool.

ous burns. To open the cooling system filler cap,

Loosen the cooling system filler cap slowly to

stop the engine and wait until the cooling system

relieve any pressure. Remove the cooling system

components are cool. Loosen the cooling system

filler cap. Remove the connection hose or remove

pressure cap slowly in order to relieve the

the cooling system drain plugs. Allow the water to

pressure.

drain. Flush the cooling system with clean water.

Check the coolant level when the engine is stopped

Install the connection hose.

and cool.

6. The drain plug O rings on the engine block must be

replaced. Clean the drain plugs and install new O

NOTICE

When any servicing or repair of the engine cooling

ring seal. Install the drain plugs and tighten to a

system is performed, the procedure must be per-

torque of 35 N·m (25 lb ft).

formed with the engine on level ground. This proce-

dure will allow you to check accurately the coolant

Fill

level. This procedure will also help in avoiding the risk

of introducing an air lock into the coolant system.

NOTICE

Do not fill the cooling system faster than 10 L

1. Remove the cooling system filler cap slowly to

(2.64 US gal) per minute to avoid air locks.

relieve pressure.

Cooling system air locks may result in engine

2. Maintain the coolant level at the maximum mark

damage.

that is correct for your application. If the engine is

equipped with a sight glass, maintain the coolant

1. Fill the cooling system with the coolant/antifreeze.

level to the correct level in the sight glass.

Refer to this Operation and Maintenance Manual,

“Refill Capacities and Recommendations” topic

(Maintenance Section) for more information on

cooling system specifications.

2. Start and run the engine at low idle. Increase the

engine rpm to high idle. Operate the engine to

open the engine thermostat. This operation will

allow any air in the system to be purged. Decrease

the engine speed to low idle. Stop the engine.

M0082024-03

117

Maintenance Section

Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Test for SCA Concentration

Heavy-Duty Coolant/Antifreeze and SCA

NOTICE

Do not exceed the recommended six percent supple-

mental coolant additive concentration.

Use a Coolant Conditioner Test Kit to check the

concentration of the SCA.

Add the SCA, If Necessary

NOTICE

Do not exceed the recommended amount of supple-

mental coolant additive concentration. Excessive

supplemental coolant additive concentration can form

deposits on the higher temperature surfaces of the

cooling system, reducing the engine's heat transfer

characteristics. Reduced heat transfer could cause

cracking of the cylinder head and other high tempera-

ture components. Excessive supplemental coolant

Illustration 72

g02590196

additive concentration could also result in radiator

Typical filler cap gaskets

tube blockage, overheating, and/or accelerated water

pump seal wear. Never use both liquid supplemental

coolant additive and the spin-on element (if

3. Clean the cooling system filler cap and check the

equipped) at the same time. The use of those addi-

condition of the filler cap gaskets. Replace the

tives together could result in supplemental coolant

cooling system filler cap if the filler cap gaskets are

additive concentration exceeding the recommended

damaged. Reinstall the cooling system filler cap.

maximum.

4. Inspect the cooling system for leaks.

Note: The Diesel Exhaust Fluid (DEF) tank requires

coolant flow around the tank. The Coolant Diverter

Valve (CDV) will turn the flow on or off. If the coolant

Pressurized System: Hot coolant can cause seri-

system has been filled with the CDV in the closed

ous burns. To open the cooling system filler cap,

position, coolant level will drop because of the

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

opening of the CDV. The coolant flow will be diverted

pressure cap slowly in order to relieve the

when the ambient temperature is continuously at

pressure.

-5° C (23° F) and for a short period after each

engine start.

NOTICE

i07682818

When any servicing or repair of the engine cooling

system is performed the procedure must be per-

Cooling System Supplemental

formed with the engine on level ground. Having the

engine level will allow you to check the coolant level

Coolant Additive (SCA) - Test/

with greater accuracy. When the engine is level, it will

also help in avoiding the risk of introducing an air lock

Add

into the coolant system.

1. Slowly loosen the cooling system filler cap to

relieve the pressure. Remove the cooling system

filler cap.

Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact

Note: Always discard drained fluids according to

with the skin and the eyes. Do not drink cooling

local regulations.

system coolant additive.

2. If necessary, drain some coolant from the cooling

system into a suitable container to allow space for

the extra SCA.

118

M0082024-03

Maintenance Section

Crankshaft Vibration Damper - Inspect

3. Add the correct amount of SCA. Refer to the

For information on removal of the crankshaft damper,

Operation and Maintenance Manual, “Refill

refer to Disassembly and Assembly, “Vibration

Damper and Pulley - Remove and Install”.

Capacities and Recommendations” for more

information on SCA requirements.

i07680861

4. Clean the cooling system filler cap and inspect the

gasket. If the gasket is damaged, discard the old

DEF Filler Screen (Emission

filler cap and install a new filler cap. If the gasket is

Related Component) - Clean

not damaged, use a suitable pressurizing pump to

pressure test the filler cap. The correct pressure is

stamped on the face of the filler cap. If the filler

cap does not retain the correct pressure, install a

NOTICE

new filler cap.

Ensure that the engine is stopped before any servic-

ing or repair is performed.

i03634651

Crankshaft Vibration Damper -

Inspect

Viscous Damper

The viscous damper has a inertia weight that is

located inside a fluid filled case. The inertia weight

moves in the case in order to limit torsional vibration.

Visually inspect the crankshaft damper. Ensure that

the cooling fins (1) on the crankshaft damper are

clean and free from dirt.

Illustration 74

g03725939

Typical example

1. Ensure that the area around cap on the Diesel

Exhaust Fluid (DEF) tank is clean. Remove cap

(1).

2. Using a suitable tool, press the tabs (2) to release

Illustration 73

g01950241

the tabs. With the tabs released remove the filter

Typical example

screen (3) from DEF tank neck adapter (4).

3. The filter screen can be cleaned in clean water and

Inspect the damper and replace the damper for any

of the following reasons:

dried using compressed air. Refer to this

Operation and Maintenance Manual, “General

• The damper is dented, cracked, or leaking.

Hazard Information” for information on using

compressed air.

M0082024-03

119

Maintenance Section

DEF Manifold Filters (Emission Related Component) - Replace

4. If the filter screen cannot be cleaned or the filter

screen is damaged, then the filter screen must be

replaced.

5. Install filter screen (3) into DEF tank neck adapter

(4). Press filter screen into neck adapter and

ensure that tabs (2) are located correctly. Install

cap (1).

i07680873

DEF Manifold Filters (Emission

Related Component) - Replace

NOTICE

Ensure that the engine is stopped before any servic-

ing or repair is performed.

NOTICE

Illustration 75

g06159487

Care must be taken to ensure that Diesel Exhaust

Fluid (DEF) for the system is contained during per-

1. Note the location of clamp (2). The clamp (2) must

formance of inspection, maintenance, testing, adjust-

be between the marked location (A).

ing, and repair of the product before opening

compartments or disassembling components con-

2. Loosen clamp (2) and remove outer filter (3) from

taining fluid have containers ready to collect these

DEF tank header (1) and discard outer filter (3).

fluids.

Dispose of all fluids according to local regulations

and mandates.

Ensure that the area around the DEF manifold is free

from contamination before any servicing or repair is

performed.

To remove the DEF manifold and the hoses

connections from the DEF tank, refer to Disassembly

and Assembly, Manifold (DEF Heater) - Remove and

Install.

Illustration 76

g06159580

3. Remove screws (7) and remove retaining plate (6).

4. Remove DEF filter (5) from pickup tube (4) and

discard the used filter (5).

5. Install new filter (5) onto pickup tube (4).

120

M0082024-03

Maintenance Section

Diesel Exhaust Fluid (Emission Related Component) - Fill

6. Install the retaining plate (6) and install screws (7).

Tighten screws (7) to a torque of 1.1 N·m

(9.8 lb in).

7. Install new outer filter (3) onto DEF tank header

(1). Ensure that the clamp (2) is located between

the location points (A).

8. Tighten clamp (2) to a torque of 4.5 N·m (40 lb in).

9. Install the DEF tank header, refer to Disassembly

and Assembly, Manifold (DEF Heater) - Remove

and Install.

i07678991

Diesel Exhaust Fluid

(Emission Related

Component) - Fill

Illustration 78

g03417998

Refer to the Original Equipment Manufacture (OEM)

Typical example

information for the Diesel Exhaust Fluid (DEF) tank

capacity.

Ensure that the correct specification Diesel Exhaust

Fluid (DEF) is used. Ensure the cleanliness of the

DEF, refer to this Operation and Maintenance

Manual, “Fluid Recommendations” for more

information.

Care should be taken when dispensing DEF. Spills

should be cleaned immediately. All surfaces should

be wiped clean and rinsed with water.

DEF that has been spilt will crystallize when the

water within the liquid evaporates. Spilt DEF will

attack paint and metal. If DEF is spilt, wash the area

with water.

Caution should be used when dispensing DEF near

an engine that has recently been running. Spilling

Illustration 77

g03379943

DEF onto hot components may cause the release of

ammonia vapors. Do not breathe ammonia vapors.

Lockable type DEF Filler cap

Do not clean up any spills with bleach.

1. Ensure that the engine is stopped. Ensure that the

DEF cap (1) and the surrounding area are clean

and free from dirt.

2. Remove the DEF cap from the tank.

3. Fill the tank with the required amount of DEF.

Ensure that dirt is not introduced into the tank

during filling. Do not over fill the tank. The DEF

may require room for expansion.

Note: Always fill the DEF tank on level ground. Cold

weather can affect DEF, refer to this Operation and

Maintenance Manual, “Diesel Exhaust Fluid in cold

Weather” for more information.

M0082024-03

121

Maintenance Section

Diesel Exhaust Fluid Filter (Emission Related Component) - Replace

4. The opening on the DEF tank (2) is a special

diameter. Ensure that the correct nozzle is used

when filling the DEF tank.

5. Check the cleanliness of DEF cap and install the

DEF cap.

i07678995

Diesel Exhaust Fluid Filter

(Emission Related

Component) - Replace

Personal injury can result from improper han-

dling of chemicals.

Make sure you use all the necessary protective

equipment required to do the job.

Make sure that you read and understand all direc-

tions and hazards described on the labels and

material safety data sheet of any chemical that is

used.

Observe all safety precautions recommended by

the chemical manufacturer for handling, storage,

and disposal of chemicals.

The Diesel Exhaust Fluid (DEF) pump can be located

next to the DEF tank. On some application the DEF

pump can be installed away from the DEF tank.

Illustration 79

g06215651

Typical example

1. Ensure that the area around the DEF filter is clean

and free from dirt. Use a 27mm Bi-Hex socket to

remove filter cap (4).

2. Remove the expansion device (3).

122

M0082024-03

Maintenance Section

Diesel Exhaust Fluid Tank - Flush

i07711082

Diesel Exhaust Fluid Tank -

Flush

Illustration 80

g06215916

Typical example

3. Use supplied tool (5) to remove filter element (2)

from DEF pump assembly (1).

4. Install new filter element (2) into DEF pump

assembly (1).

Illustration 81

g03676503

Typical example

5. Install expansion device (3) into filter element (2).

Install filter cap (4) and tighten cap to 20 N·m

If contamination of the Diesel Exhaust Fluid (DEF) is

(15 lb ft).

suspected, the DEF tank (3) will need to be drained

and the DEF tank flushed.

1. Ensure that the purging of the DEF system has

been completed.

2. After the completion of the purging, Isolate the

power, refer to this Operation and Maintenance

Manual, “Battery Disconnect Switch” for more

information.

Note: Ensure that the vessel that will be used is large

enough to collect the fluid to be drained.

3. Position the vessel below the drain plug (4).

Remove the filler cap (1). Remove the drain plug

and allow the fluid to drain.

4. Remove the Manifold (DEF Heater) (2). Refer to

Disassembly and Assembly, “Manifold (DEF

Heater)-Remove and Install” after draining the

fluid.

5. If necessary, remove the DEF filler screen. For

more information, refer to this Operation and

Maintenance Manual, “DEF Filler Screen - Clean”.

M0082024-03

123

Maintenance Section

Driven Equipment - Check

The DEF tank must be flushed after draining.

NOTICE

Flush the tank with deionized water. Ensure that

Accumulated grease and oil on an engine is a fire

all the flushing agents have been drained.

hazard. Keep the engine clean. Remove debris and

fluid spills whenever a significant quantity accumu-

6. Install the Manifold (DEF Heater) (2). Refer to

lates on the engine.

Disassembly and Assembly, “Manifold (DEF

Heater)-Remove and Install”.

Periodic cleaning of the engine is recommended.

Steam cleaning the engine will remove accumulated

7. If necessary, install the DEF filler screen. For more

oil and grease. A clean engine provides the following

information, refer to this Operation and

benefits:

Maintenance Manual, “DEF Filler Screen - Clean”.

• Easy detection of fluid leaks

8. Install the drain plug (4). Tighten the drain plug to a

torque of 6 N·m (53 lb in). Remove the vessel

• Maximum heat transfer characteristics

used for draining. Dispose of the drained fluid in

• Ease of maintenance

accordance with local regulation.

Note: Caution must be used to prevent electrical

9. Refill the DEF tank (3).After the tank has been

components from being damaged by excessive water

filled, connect the electrical supply. Refer to this

when the engine is cleaned. Pressure washers and

Operation and Maintenance Manual, “Diesel

steam cleaners should not be directed at any

Exhaust Fluid - Fill” for more information.

electrical connectors or the junction of cables into the

If the DEF tank has been fill with another fluid other

rear of the connectors. Avoid electrical components

than DEF, then contact your Perkins distributor.

such as the alternator, the starter, and the ECM.

Protect the fuel injection pump from fluids to wash the

i02151646

engine.

Ensure that care is taken that the safety labels,

Driven Equipment - Check

emission label, and all other information labels are

not removed during engine cleaning.

Refer to the OEM specifications for more information

Aftertreatment

on the following maintenance recommendations for

the driven equipment:

During the engine cleaning process, ensure that

water or cleaning fluids cannot enter the

• Inspection

aftertreatment system. If cleaning fluids enters the

aftertreatment system, damage could occur.

• Adjustment

• Lubrication

i07161989

• Other maintenance recommendations

Engine Air Cleaner Element -

Perform any maintenance for the driven equipment

Replace

which is recommended by the OEM.

i07819515

NOTICE

Never run the engine without an air cleaner element

Engine - Clean

installed. Never run the engine with a damaged air

cleaner element. Do not use air cleaner elements

with damaged pleats, gaskets or seals. Dirt entering

the engine causes premature wear and damage to

engine components. Air cleaner elements help to pre-

vent airborne debris from entering the air inlet.

Personal injury or death can result from high

voltage.

NOTICE

Moisture

can

create

paths

electrical

Never service the air cleaner element with the engine

conductivity.

running since this will allow dirt to enter the engine.

Make sure that the electrical system is OFF. Lock

Ensure that the engine cannot start before any

out the starting controls and tag the controls “DO

service or repair is performed.

NOT OPERATE” .

124

M0082024-03

Maintenance Section

Engine Air Cleaner Service Indicator - Inspect

Servicing the Air Cleaner Element

2. Remove the end cap (1). Remove the air filter

element within the main body (2), if a secondary

Note: The air filter system may not have been

filter element is installed then, remove the

provided by Perkins. The procedure that follows is for

secondary filter element. Discard all old elements.

a typical air filter system. Refer to the OEM

information for the correct procedure.

3. If equipped install the new secondary filter

element. Install the primary filter element.

If the air cleaner element becomes plugged, the air

can split the material of the air cleaner element.

4. Ensure that the end cover (1) is clean and free

Unfiltered air will drastically accelerate internal

from dirt and dust. Check the condition of the valve

engine wear. Refer to the OEM information for the

(5), also check the operation of the valve. If

correct air cleaner elements for your application.

necessary replace the valve.

• Check the air cleaner service indicator daily.

5. Install the end cap (1) to the main body (2). Check

and if necessary, reset the service indicator (4).

• Check the pre-cleaner (if equipped) and the dust

bowl daily for accumulation of dirt and debris.

i02335405

Remove any dirt and debris, as needed.

• Operating in dirty conditions may require more

Engine Air Cleaner Service

frequent service of the air cleaner element.

Indicator - Inspect

Replace the dirty air cleaner elements with new air

cleaner elements. Before installation, the air cleaner

elements should be thoroughly checked for tears

Some engines may be equipped with a different

and/or holes in the filter material. Inspect the gasket

service indicator.

or the seal of the air cleaner element for damage.

Maintain a supply of suitable air cleaner elements for

Some engines are equipped with a differential gauge

replacement purposes.

for inlet air pressure. The differential gauge for inlet

air pressure displays the difference in the pressure

that is measured before the air cleaner element and

the pressure that is measured after the air cleaner

element. As the air cleaner element becomes dirty,

the pressure differential rises. If your engine is

equipped with a different type of service indicator,

follow the OEM recommendations in order to service

the air cleaner service indicator.

The service indicator may be mounted on the air

cleaner element or in a remote location.

Illustration 82

g06239375

Typical example

(1) End cover

Illustration 83

g00103777

(2) Main body

Typical service indicator

(3) Rain cap

(4) Service indicator

(5) Valve

Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner element

should be replaced when one of the following

1. If the air cleaner as a primary filter element

conditions occur:

installed, and a secondary filter element installed,

both filter elements must be replaced.

• The yellow diaphragm enters the red zone.

M0082024-03

125

Maintenance Section

Engine Air Precleaner - Check/Clean

• The red piston locks in the visible position.

i08412716

Test the Service Indicator

Engine Crankcase Breather

Element (Emission Related

Service indicators are important instruments.

Component) - Replace

• Check for ease of resetting. The service indicator

should reset in less than three pushes.

(Type 2)

• Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.

The yellow core should latch at the greatest

vacuum that is attained.

Hot oil and hot components can cause personal

If the service indicator does not reset easily, or if the

injury. Do not allow hot oil or hot components to

yellow core does not latch at the greatest vacuum,

contact the skin.

the service indicator should be replaced. If the new

service indicator will not reset, the hole for the service

indicator may be restricted.

NOTICE

Ensure that the engine is stopped before any servic-

The service indicator may need to be replaced

ing or repair is performed.

frequently in environments that are severely dusty.

The crankcase breather is a very important

i07819526

component in order to keep your engine emissions

compliant.

Engine Air Precleaner - Check/

• The filter element within the crankcase breather

Clean

must be serviced at the prescribed service

interval.

• The correct filter element must be installed before

the engine is operated.

• The installation of the filter element is very

important.

• The quality of the filter element that is installed is

very important.

• The filter element protects the engine from

excessive quantities of oil from entering the

induction system. The filter element also protects

the engine aftertreatment system.

Note: Excessive quantities of oil that enter the

induction system of the engine can rapidly increase

Illustration 84

g01453058

the engine speed without control.

Typical engine air precleaner

For information on aftermarket products, refer to

(1) Wing nut

Operation and Maintenance Manual, “Engine

(2) Cover

Description”. Within that section, refer to the title

(3) Body

“Aftermarket Products and Caterpillar Engines”.

Remove wing nut (1) and cover (2). Check for an

accumulation of dirt and debris in body (3). Clean the

body, if necessary.

After cleaning the precleaner, install cover (2) and

wing nut (1).

Note: When the engine is operated in dusty

conditions, more frequent cleaning is required.

Do not tap or strike the air cleaner element.

126

M0082024-03

Maintenance Section

Type 2

Illustration 85

g06623961

Illustration 86

g01884135

Typical example

(B) Alignment position

1. Ensure that dirt cannot enter the breather

Note: The cut away from section (5) in the cap allows

assembly. Ensure that the outside body of the

access to the seal.

breather assembly is clean and free from damage.

4. Remove the old seal (4) and install a new seal.

Place a container under the breather assembly.

5. Install a new filter element into the breather body

2. Rotate the cap (1) counterclockwise into the

(3) and orient the filter element so that position (A)

unlocked position. Remove the cap from the body

is aligned. Refer to illustration 85 . Align position

of the breather (3).

(A) on the filter element to position (B) on the cap.

Note: The cap (1) is tightened or loosened by hand.

If the cap (1) is difficult to remove, use a suitable tool

to apply a suitable force to assist the removal of the

cap (1). Care should be taken, as excessive force

may cause damage to the cap (1).

3. Note the orientation of the filter element (2).

Remove the filter element .

Illustration 87

g06623944

Typical example

6. Install the cap (1). Rotate the cap by hand

clockwise until the cap locks into the locked

position C on the breather body.

7. Remove the container.

M0082024-03

127

Maintenance Section

Engine Crankcase Breather Element (Emission Related Component) - Replace

Check the System

The crankcase breather is a very important

component to keep your engine emissions compliant.

• The filter element within the crankcase breather

must be serviced at the prescribed service

interval.

• The correct filter element must be installed before

the engine is operated.

• The installation of the filter element is very

important.

• The quality of the filter element that is installed is

very important.

For information on aftermarket products, refer to

Operation and Maintenance Manual, “Engine

Description”. Within that section, refer to the title

“Aftermarket Products and Perkins Engines”.

The breather element can be serviced from the top

position or the breather element can be serviced from

the bottom position.

Top Service

Illustration 88

g02416001

(1) Connection to breather cap for the engine

(2) Oil drain

(3) Tube assembly to atmosphere

(4) Outlet

Check the system for damage. Replace any

component that is damaged. Ensure that the outlet

(4) is clear and free from obstructions.

i08414736

Engine Crankcase Breather

Element (Emission Related

Component) - Replace

(Type 1)

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to

Illustration 89

g03090965

contact the skin.

1. Ensure that dirt cannot enter the breather

assembly. Ensure that the outside body of the

NOTICE

Ensure that the engine is stopped before any servic-

breather assembly is clean and free from damage.

ing or repair is performed.

Place a container under the breather assembly.

128

M0082024-03

Maintenance Section

Type 1

2. Rotate the top cap (1) counterclockwise into the

unlocked position. Remove the top cap from the

body of the breather (3).

Note: The cap (1) is tightened or loosened by hand.

If the cap (1) is difficult to remove, use a suitable tool

to apply a suitable force to assist the removal of the

cap (1). Care should be taken, as excessive force

may cause damage to the cap (1).

3. Note the orientation of the filter element (2).

Remove the filter element.

Illustration 91

g03090938

(A) Alignment position

(B) Alignment position

5. Install a new filter element into the breather body

(3). Ensure the correct position of the element,

Illustration 90

g03090963

refer to illustration 91 . Align position (A) on the top

cap to position (B) on the filter element.

4. Remove the old seal (4) and install a new seal.

Note: The cut away from section (5) in the top cap

allows access to the seal.

Illustration 92

g02346577

Typical example

M0082024-03

129

Maintenance Section

Type 1

6. Install the top cap (1). Rotate the top cap by hand

clockwise until the top cap locks into the locked

position (C) on the breather body.

7. Remove the container.

Bottom Service

Ensure that dirt cannot enter the breather assembly.

Illustration 94

g03090968

Typical example

(A) Alignment postion

Illustration 93

g02346498

(B) Alignment postion

Typical example

(X) Alignment mark

3. Remove the filter element (4). Remove the seal

(Y) Alignment mark

(5).

1. Ensure that the outside body of the breather

Note: The bottom cap has a section that allows

assembly is clean and free from damage. Place a

access to remove the seal.

container under the breather.

4. Install a new seal (5). Install a new filter element

2. Remove tube connection (1). Ensure that dirt

into the bottom cap (2).

cannot enter the tube connection. Note the

5. Align position (A) on the top cap to position (B) on

position of the alignment marks (X and Y). Rotate

the filter element. Refer to illustration 94 .

the bottom cap (2) counterclockwise to release the

cap and the filter element (4) from the breather

6. Install the assembly of the filter element and the

body (3).

bottom cap (2). Rotate the bottom cap by hand

clockwise until the bottom cap locks into the

locked position on the breather body. Ensure that

the alignment marks (X and Y) are correctly

aligned. Refer to illustration 93 .

130

M0082024-03

Maintenance Section

Engine Mounts - Inspect

7. Install tube connection (1). Ensure that the

When the engine mounts are supplied by Perkins the

retaining clips on the tube connection are correctly

maintenance procedure will be supplied in the

Disassembly and Assembly manual for your engine.

engaged. Remove the container.

i05300117

Check the System

Engine Oil Level - Check

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to

contact the skin.

Illustration 95

g02346500

Typical example

Illustration 96

g02173847

Inspect the breather outlet pipe (1) for damage.

Ensure that the outlet (2) is clean and free from any

“L” Low

obstructions. Ice can cause obstructions in adverse

“H” High

weather conditions.

i07819538

NOTICE

Perform this maintenance with the engine stopped.

Engine Mounts - Inspect

Note: Ensure that the engine is either level or that

the engine is in the normal operating position in order

Note: The engine mounts may not have been

to obtain a true level indication.

supplied by Perkins. Refer to the Original Equipment

Note: After the engine has been switched OFF, wait

Manufacturer (OEM) information for further details on

for 10 minutes in order to allow the engine oil to drain

the engine mounts and the correct bolt torque.

to the oil pan before checking the oil level.

Inspect the engine mounts for deterioration and for

correct bolt torque. Excessive engine vibration can

1. Maintain the oil level between the mark (L) and the

be caused by the following conditions:

mark (H) on the engine oil dipstick. Do not fill the

crankcase above the “H” .

• Incorrect mounting of the engine

NOTICE

• Deterioration of the engine mounts

Operating your engine when the oil level is above the

“H” mark could cause your crankshaft to dip into the

• Loose engine mounts

oil. The air bubbles created from the crankshaft dip-

ping into the oil reduces the oils lubricating character-

Any engine mount that shows deterioration should be

istics and could result in the loss of power.

replaced. Refer to the OEM information for the

recommended torques.

2. Remove the oil filler cap and add oil, if necessary.

Clean the oil filler cap. Install the oil filler cap.

M0082024-03

131

Maintenance Section

Engine Oil Sample - Obtain

If an increase in the oil level is noticed, refer to

The sample can be checked for the following: the

Troubleshooting, “Oil Contains Fuel”.

quality of the oil, the existence of any coolant in the

oil, the existence of any ferrous metal particles in the

i01907674

oil and the existence of any nonferrous metal

particles in the oil.

Engine Oil Sample - Obtain

i07074312

Engine Oil and Filter - Change

The condition of the engine lubricating oil may be

checked at regular intervals as part of a preventive

maintenance program. Perkins include an oil

sampling valve as an option. The oil sampling valve

(if equipped) is included in order to regularly sample

the engine lubricating oil. The oil sampling valve is

positioned on the oil filter head or the oil sampling

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to

valve is positioned on the cylinder block.

contact the skin.

Perkins recommends using a sampling valve in order

to obtain oil samples. The quality and the consistency

of the samples are better when a sampling valve is

NOTICE

used. The location of the sampling valve allows oil

Care must be taken to ensure that fluids are con-

that is flowing under pressure to be obtained during

tained during performance of inspection, mainte-

normal engine operation.

nance, testing, adjusting and repair of the product.

Be prepared to collect the fluid with suitable contain-

ers before opening any compartment or disassem-

Obtain the Sample and the

bling any component containing fluids.

Analysis

Dispose of all fluids according to local regulations

and mandates.

Hot oil and hot components can cause personal

NOTICE

injury. Do not allow hot oil or hot components to

Keep all parts clean from contaminants.

contact the skin.

Contaminants may cause rapid wear and shortened

In order to help obtain the most accurate analysis,

component life.

record the following information before an oil sample

is taken:

Do not drain the engine lubricating oil when the

engine is cold. As the engine lubricating oil cools,

• The date of the sample

suspended waste particles settle on the bottom of the

oil pan. The waste particles are not removed with

• Engine model

draining cold oil. Drain the oil pan with the engine

stopped. Drain the oil pan with the oil warm. This

• Engine number

draining method allows the waste particles that are

suspended in the oil to be drained properly.

• Service hours on the engine

Failure to follow this recommended procedure will

• The number of hours that have accumulated since

cause the waste particles to be recirculated through

the last oil change

the engine lubrication system with the new oil.

• The amount of oil that has been added since the

Oil and Filter Change Intervals

last oil change

Ensure that the container for the sample is clean and

The standard engine oil and filter change period is

dry. Also ensure that the container for the sample is

500 hours. There are several other factors that can

alter the standard engine oil and filter change of 500

clearly labelled.

hours.

To ensure that the sample is representative of the oil

• If the engine is using engine oil analysis to

in the crankcase, obtain a warm, well mixed oil

sample.

determine oil and filter change period.

To avoid contamination of the oil samples, the tools

• The engine is working in a severe service

and the supplies that are used for obtaining oil

environment/Load Factor

samples must be clean.

• Infrequent operation of the engine

132

M0082024-03

Maintenance Section

Engine Oil and Filter - Change

Refer to this Operation and Maintenance Manual,

After the oil has drained, the oil drain plugs should be

“Severe Service Application” for more information on

cleaned and installed. If necessary, replace the O

reducing the engine oil and filter change period. For

ring seal. Tighten the drain plug to 34 N·m (25 lb ft).

severe service applications the recommended oil and

filter change period is 250 hours.

Replace the Oil Filter

If the engine is operated in severe service conditions,

Perkins recommends the use of engine oil sampling.

NOTICE

Refer to this Operation and Maintenance Manual,

Perkins oil filters are manufactured to Perkins specifi-

Engine Oil sample - Obtain for more information.

cations. Use of an oil filter that is not recommended

by Perkins could result in severe damage to the en-

If the engine is operated infrequently less than 500

gine bearings, crankshaft, and so forth. As a result of

hours in a 12-month period, then the engine oil and

the larger waste particles from unfiltered oil entering

filter change should be conducted yearly.

the engine lubricating system. Only use oil filters rec-

ommended by Perkins.

Drain the Engine Lubricating Oil

1. Remove the oil filter with a suitable tool.

Note: Ensure that the vessel that will be used is large

enough to collect the waste oil.

Note: The following actions can be carried out as

part of the preventive maintenance program.

After the engine has been run at the normal

operating temperature, stop the engine. Use one of

2. Cut the oil filter open with a suitable tool. Break

the following methods to drain the engine oil pan:

apart the pleats and inspect the oil filter for metal

debris. An excessive amount of metal debris in the

oil filter may indicate early wear or a pending

failure.

Use a magnet to differentiate between the ferrous

metals and the nonferrous metals that are found in

the oil filter element. Ferrous metals may indicate

wear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on the

aluminum parts, brass parts, or bronze parts of the

engine. Parts that may be affected include the

following items: main bearings, rod bearings, and

turbocharger bearings.

During to normal wear small amounts of debris

may be found in the oil filter.

Illustration 97

g01880893

Typical example

• If the engine is equipped with a drain valve, turn

the drain valve knob counterclockwise to drain the

oil. After the oil has drained, turn the drain valve

knob clockwise to close the drain valve.

• If the engine is not equipped with a drain valve,

remove the oil drain plug (1) to allow the oil to

drain. If the engine is equipped with a shallow oil

pan, remove the bottom oil drain plugs from both

ends of the oil pan.

M0082024-03

133

Maintenance Section

Fan Clearance - Check

2. Start the engine and run the engine at “LOW IDLE”

for 2 minutes. Perform this procedure to ensure

that the lubrication system has oil and that the oil

filters are filled. Inspect the oil filter for oil leaks.

3. Stop the engine and allow the oil to drain back to

the oil pan for a minimum of 10 minutes.

Illustration 98

g02351361

Typical example

Illustration 99

g02173847

“L” Low

3. Clean sealing surface (2).

“H” High

4. Apply clean engine oil to O ring seal (3) for the new

4. Remove the engine oil level gauge to check the oil

oil filter.

level. Maintain the oil level between the “L” and “H”

marks on the engine oil level gauge. Do not fill the

NOTICE

Do not fill the oil filters with oil before installing them.

crankcase above the “H” mark.

This oil would not be filtered and could be contami-

nated. Contaminated oil can cause accelerated wear

i05404932

to engine components or engine damage.

Fan Clearance - Check

5. Install the new oil filter. Spin on the oil filter until the

O ring contacts the sealing surface (2). Then

rotate the oil filter ¾ of a full turn.

There are different types of cooling systems that can

be installed. Refer to the Original Equipment

Manufactory (OEM) for your application for more

Fill the Oil Pan

information.

1. Remove the oil filler cap. Refer to this Operation

Ensure that the engine is stopped and allow 2

and Maintenance Manual, “Fluid

minutes before the battery disconnect switch is

Recommendations” for more information on

turned off. This procedure will allow the Diesel

Exhaust Fluid (DEF) system to purged.

suitable oils. Fill the oil pan with the correct

amount of new engine lubricating oil. Refer to this

Ensure that the cooling system is full before checking

Operation and Maintenance Manual, “Refill

the fan tip clearance. The fan tip clearance is the

Capacities” for more information on refill

distance between the tip of the fan blade (2) and the

capacities.

edge of the cover (1).

NOTICE

If equipped with an auxiliary oil filter system or a re-

mote filter system, follow the OEM or the filter manu-

factures recommendations. Under-filling or over filling

the crankcase with oil can cause engine damage.

134

M0082024-03

Maintenance Section

Fuel Filter (In-Line) - Replace

Illustration 100

g03414037

Typical example

The gap (A) must be checked in the vertical position

i05814842

and in the horizontal position.

Fuel Filter (In-Line) - Replace

In the vertical position the gap can be checked at the

vertically top position or at the vertically bottom

position.

• Gap (A) vertical top position 12 ± 1 mm

(0.47244 ± 0.03937 inch).

Fuel leaked or spilled onto hot surfaces or electri-

• Gap (A) vertical bottom position 8 ± 1 mm

cal components can cause a fire. To help prevent

possible injury, turn the start switch off when

(0.31496 ± 0.03937 inch).

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

After the gap (A) has been checked in the vertical top

position or the vertical bottom position, the horizontal

position must be checked.

Note: Refer to Systems Operation, Testing, and

• Gap (A) in the horizontal position must be a

Adjusting, “Cleanliness of Fuel System

minimum of 9 mm (0.35433 inch).

Components” for detailed information on the

standards of cleanliness that must be observed

If the fan tip clearance requires adjustment, refer to

during ALL work on the fuel system.

the Disassembly and Assembly manual for more

information.

M0082024-03

135

Maintenance Section

Fuel System - Prime

i05774864

NOTICE

Ensure that the engine is stopped before any servic-

ing or repair is performed.

Fuel System - Prime

The location of the in-line fuel filter will depend on the

application that the engine has been installed.

Note: Refer to Systems Operation, Testing, and

Adjusting, “Cleanliness of Fuel System

Components” for detailed information on the

standards of cleanliness that must be observed

during ALL work on the fuel system.

Ensure that all adjustments and repairs are

performed by authorized personnel that have had the

correct training.

NOTICE

Do not crank the engine continuously for more than

30 seconds. Allow the starting motor to cool for two

minutes before cranking the engine again.

If air enters the fuel system, the air must be purged

from the fuel system before the engine can be

started. Air can enter the fuel system when the

following events occur:

• The fuel tank is empty or the fuel tank has been

partially drained.

• The low-pressure fuel lines are disconnected.

Illustration 101

g03086919

Typical example

• A leak exists in the low-pressure fuel system.

1. Turn the fuel supply valve (if equipped) to the OFF

• The fuel filter has been replaced.

position. Remove any brackets that hold the in-line

Use the following procedures in order to remove air

fuel filter (1) in place, refer to OEM information.

from the fuel system:

2. Release the hose clips (3) and remove the hose

1. Ensure that the fuel system is in working order.

lines from the in-line fuel filter. Remove the in-line

Check that the fuel supply valve (if equipped) is in

filter.

the “ON” position.

3. Install a new in-line filter and secure, refer to OEM

2. Turn the keyswitch to the “RUN” position.

information. Ensure that the arrow mark (2) is

aligned to the direction of fuel flow from the tank to

3. The keyswitch will allow the electric priming pump

the fuel pump.

to operate. Operate the electric priming pump. The

ECM will stop the pump after 2 minutes.

4. Install the fuel hose lines and install the hose clips

(3). Turn the fuel supply valve (if equipped) to the

4. Turn the keyswitch to the “OFF” position. The fuel

ON position.

system should now be primed and the engine

should be able to start.

5. The in-line fuel filter must be changed with the

primary filter and the secondary fuel filter. The fuel

5. Operate the engine starter and crank the engine.

system will need to be primed, refer to Operation

After the engine has started, operate the engine at

and Maintenance Manual, “Fuel System - Prime”

low idle for a minimum of 5 minutes. Ensure that

for more information.

the fuel system is free from leaks.

Note: Operating the engine for this period will help

ensure that the fuel system is free of air. DO NOT

loosen the high-pressure fuel lines in order to

purge air from the fuel system. This procedure is

not required.

136

M0082024-03

Maintenance Section

Fuel System Primary Filter (Water Separator) Element - Replace

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. The 10 minute wait will also allow static charge

to dissipate from the low-pressure fuel system. 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”.

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”.

If the engine will not start, refer to Troubleshooting,

“Engine Cranks but will not Start”.

i06217529

Fuel System Primary Filter

Illustration 102

g03858194

Typical example

(Water Separator) Element -

Replace

3. Install a suitable tube onto drain (3). Open the

drain valve (2). Rotate the drain valve

counterclockwise. Two full turns are required.

4. Loosen the vent screw (1).

5. Allow the fuel to drain into the container. If the fuel

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent

will not drain, loosen the vent screw on the

possible injury, turn the start switch off when

secondary fuel filter.

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

Note: In some applications, the vent screw on the

secondary fuel filter will need to be open in order to

drain the primary fuel filter.

Note: Refer to Systems Operation, Testing, and

Adjusting, “Cleanliness of Fuel System

6. Remove the tube from the drain valve.

Components” for detailed information on the

7. Tighten the vent screw (1) to a torque of 2.5 N·m

standards of cleanliness that must be observed

during ALL work on the fuel system.

(22 lb in). If necessary, tighten the vent screw on

the secondary fuel filter. Tighten to a torque of

2.5 N·m (22 lb in). Remove the wiring harness

NOTICE

Ensure that the engine is stopped before any servic-

from connection (4).

ing or repair is performed.

8. Rotate filter bowl (6) counterclockwise and remove

the filter bowl from assembly.

Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFF

position before performing this maintenance.

2. Place a suitable container under the water

separator in order to catch any fuel that might spill.

Clean up any spilled fuel. Clean the outside body

of the filter assembly.

M0082024-03

137

Maintenance Section

Fuel System Primary Filter (Water Separator) Element - Replace

9. Rotate the filter element (5) counterclockwise and

remove the filter element . Clean the filter bowl.

Install the New Filter Element

Illustration 103

g03858640

Typical example

Illustration 104

g03086798

Typical example

1. Locate the thread in the new filter element (8) onto

the threads (9). Spin on the filter element and

tighten the drain valve (2) securely.

2. Lubricate the O ring seal (7) with clean engine oil.

Do NOT fill the bowl with fuel before the assembly

is installed.

3. Do not use a tool in order to install the filter

assembly. Tighten the filter bowl (6) by hand.

Install the filter bowl (6). Turn the filter bowl

clockwise until the filter bowl locks into position

against the stops.

4. Remove the container and dispose of the fuel in a

safe place.

138

M0082024-03

Maintenance Section

Fuel System Primary Filter/Water Separator - Drain

5. The secondary filter element must be replaced at

the same time as the primary filter element. Also,

the in-line filter must be changed. Refer to the

Operation and Maintenance Manual , “Fuel

System Filter - Replace”.

i06891342

Fuel System Primary Filter/

Water Separator - Drain

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent

possible injury, turn the start switch off when

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

Illustration 105

g03858194

NOTICE

Typical example

Ensure that the engine is stopped before any servic-

ing or repair is performed.

3. Install a suitable tube onto drain (3). Open the

drain valve (2). Rotate the drain valve

counterclockwise. Two full turns are required.

NOTICE

Loosen vent screw (1).

The water separator can be under suction during nor-

mal engine operation. Ensure that the drain valve is

4. Visually check that the fluid will drain. Allow the

tightened securely to help prevent air from entering

fluid to drain into the container.

the fuel system.

5. When fluid free from water comes from the primary

fuel filter, tighten the drain valve clockwise by hand

Drain Procedure

pressure only. Remove the tube and remove the

container.

1. Place a suitable container under the water

6. Tighten the vent screw to a torque of 2.5 N·m

separator to catch any fluid that might spill. Clean

(22 lb in).

up any spilled fluid.

2. Ensure that the outer body of the filter assembly is

i06217548

clean and free from dirt.

Fuel System Secondary Filter -

Replace

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent

possible injury, turn the start switch off when

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

NOTICE

Ensure that the engine is stopped before any servic-

ing or repair is performed.

M0082024-03

139

Maintenance Section

Fuel System Secondary Filter - Replace

Refer to Systems Operation, Testing, and

Adjusting, “Cleanliness of Fuel System

Components” for detailed information on the

standards of cleanliness that must be observed

during ALL work on the fuel system.

Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFF

position before performing this maintenance.

2. Place a suitable container under the fuel filter in

order to catch any fuel that might spill. Clean up

any spilled fuel. Clean the outside body of the filter

assembly.

Illustration 107

g02546456

7. Rotate the filter element (5) counterclockwise and

remove the filter element. Clean the filter bowl.

Install the Element

Illustration 106

g03088718

3. Install a suitable tube onto drain (4). Open the

drain valve (3). Rotate the drain valve

counterclockwise. Two full turns are required.

Loosen vent screw (1).

4. Allow the fuel to drain into the container and

remove the tube.

5. Tighten the vent screw (1) to a torque of 2.5 N·m

(22 lb in).

6. Remove the filter bowl (2). Rotate the filter

assembly counterclockwise in order to remove the

Illustration 108

g03088837

assembly.

1. Locate the thread (7) in the filter element onto the

threads (8). Spin on the element and tighten the

drain valve (3) by hand.

2. Lubricate the O ring seal (6) with clean engine oil.

Do NOT fill the filter bowl (2) with fuel before the

filter assembly is installed.

140

M0082024-03

Maintenance Section

Fuel Tank Water and Sediment - Drain

3. Do not use a tool in order to install the filter

Open the drain valve on the bottom of the fuel tank in

assembly. Tighten the assembly by hand. Install

order to drain the water and the sediment. Close the

drain valve.

the filter bowl (2). Turn the filter bowl clockwise

until the filter bowl locks into position against the

Check the fuel daily. Allow five minutes after the fuel

stops.

tank has been filled before draining water and

sediment from the fuel tank.

4. Turn the fuel supply valve to the ON position.

Fill the fuel tank after operating the engine in order to

5. The primary fuel filter the secondary fuel filter must

drive out moist air. This will help prevent

be replaced at the same time. Refer to the

condensation. Do not fill the tank to the top. The fuel

Operation and Maintenance Manual , “Fuel

expands as the fuel gets warm. The tank may

overflow.

System Primary Filter (Water Separator) Element -

Replace”. Also, the in-line fuel must be replaced

Some fuel tanks use supply pipes that allow water

when the primary and secondary filters are

and sediment to settle below the end of the fuel

replaced. Refer to Operation and Maintenance

supply pipe. Some fuel tanks use supply lines that

take fuel directly from the bottom of the tank. If the

Manual , “Fuel Filter (In-Line)- Replace”

engine is equipped with this system, regular

6. Prime the fuel system. Refer to the Operation and

maintenance of the fuel system filter is important.

Maintenance Manual, “Fuel System - Prime” for

more information.

Fuel Storage Tanks

i02348492

Drain the water and the sediment from the fuel

storage tank at the following intervals:

Fuel Tank Water and Sediment

• Weekly

- Drain

• Service intervals

• Refill of the tank

NOTICE

This will help prevent water or sediment from being

Care must be taken to ensure that fluids are con-

pumped from the storage tank into the engine fuel

tained during performance of inspection, mainte-

tank.

nance, testing, adjusting and repair of the product.

Be prepared to collect the fluid with suitable contain-

If a bulk storage tank has been refilled or moved

ers before opening any compartment or disassem-

recently, allow adequate time for the sediment to

bling any component containing fluids.

settle before filling the engine fuel tank. Internal

baffles in the bulk storage tank will also help trap

Dispose of all fluids according to local regulations

sediment. Filtering fuel that is pumped from the

and mandates.

storage tank helps to ensure the quality of the fuel.

When possible, water separators should be used.

Fuel Tank

i07819616

Fuel quality is critical to the performance and to the

Hoses and Clamps - Inspect/

service life of the engine. Water in the fuel can cause

excessive wear to the fuel system.

Replace

Water can be introduced into the fuel tank when the

fuel tank is being filled.

Condensation occurs during the heating and cooling

of fuel. The condensation occurs as the fuel passes

through the fuel system and the fuel returns to the

Contact with high pressure fuel may cause fluid

fuel tank. This causes water to accumulate in fuel

penetration and burn hazards. High pressure fuel

tanks. Draining the fuel tank regularly and obtaining

spray may cause a fire hazard. Failure to follow

fuel from reliable sources can help to eliminate water

these inspection, maintenance and service in-

in the fuel.

structions may cause personal injury or death.

If you inspect the engine in operation, always use the

Drain the Water and the Sediment

proper inspection procedure to avoid a fluid

penetration hazard. Refer to Operation and

Fuel tanks should contain some provision for draining

Maintenance Manual, “General hazard Information”

water and draining sediment from the bottom of the

and Operation and Maintenance Manual, “High

fuel tanks.

Pressure Fuel Lines” for the correct procedures.

M0082024-03

141

Maintenance Section

Injector (Diesel Exhaust Fluid) (Emissions Related Component) - Replace

Inspect all hoses for leaks that are caused by the

following conditions:

Pressurized System: Hot coolant can cause seri-

• Cracking

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

• Softness

components are cool. Loosen the cooling system

pressure cap slowly in order to relieve the

• Loose clamps

pressure.

Replace hoses that are cracked or soft. Tighten any

loose clamps.

1. Stop the engine. Allow the engine to cool.

Check for the following conditions:

2. Loosen the cooling system filler cap slowly to

relieve any pressure. Remove the cooling system

• End fittings that are damaged or leaking

filler cap.

• Outer covering that is chafed or cut

Note: Drain the coolant into a suitable, clean

• Exposed wire that is used for reinforcement

container. The coolant can be reused.

• Outer covering that is ballooning locally

3. Drain the coolant from the cooling system to a

level that is below the hose that is being replaced.

• Flexible part of the hose that is kinked or crushed

4. Remove the hose clamps.

• Armoring that is embedded in the outer covering

5. Disconnect the old hose.

A constant torque hose clamp can be used in place

6. Replace the old hose with a new hose.

of any standard hose clamp. Ensure that the constant

torque hose clamp is the same size as the standard

7. Install the hose clamps with a torque wrench.

clamp.

Note: For the correct coolant, see this Operation and

Due to extreme temperature changes, the hose will

Maintenance Manual, “Fluid Recommendations”.

harden. Hardening of the hoses will cause hose

clamps to loosen. This can result in leaks. A constant

8. Refill the cooling system. Refer to the OEM

torque hose clamp will help to prevent loose hose

information for further information on refilling the

clamps.

cooling system.

Each installation application can be different. The

differences depend on the following factors:

9. Clean the cooling system filler cap. Inspect the

cooling system filler cap's seals. Replace the

• Type of hose

cooling system filler cap if the seals are damaged.

Install the cooling system filler cap.

• Type of fitting material

10. Start the engine. Inspect the cooling system for

• Anticipated expansion and contraction of the hose

leaks.

• Anticipated expansion and contraction of the

i07679023

fittings

Injector (Diesel Exhaust Fluid)

Replace the Hoses and the Clamps

(Emissions Related

Refer to the OEM information for further information

Component) - Replace

on removing and replacing fuel hoses (if equipped).

The following text describes a typical method of

replacing coolant hoses. Refer to the OEM

• DEF

Diesel Exhaust Fluid

information for further information on the coolant

system and the hoses for the coolant system.

142

M0082024-03

Maintenance Section

Radiator - Clean

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a

protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction to

the fan's air flow. Hold the nozzle approximately

6 mm (0.25 inch) away from the radiator fins. Slowly

move the air nozzle in a direction that is parallel with

the radiator tube assembly. This will remove debris

that is between the tubes.

Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes

must be less than 275 kPa (40 psi). Use pressurized

Illustration 109

g06158030

water in order to soften mud. Clean the core from

both sides.

Typical example

(1) DEF injector

Use a degreaser and steam for removal of oil and

(2) DEF connector

grease. Clean both sides of the core. Wash the core

(3) Electrical connector

with detergent and hot water. Thoroughly rinse the

(4) Coolant connector

core with clean water.

For a detailed procedure to remove and install the

If the radiator is blocked internally, refer to the OEM

DEF injector (1), refer to Disassembly and Assembly,

Manual for information regarding flushing the cooling

DEF Injector and Mounting - Remove and Install.

system.

After installation of the DEF injector, use the

After cleaning the radiator, start the engine. Allow the

electronic service tool to perform the “DEF Dosing

engine to operate at low idle speed for three to five

System Verification test” .

minutes. Accelerate the engine to high idle. This will

help in the removal of debris and the drying of the

i02335774

core. Slowly reduce the engine speed to low idle and

then stop the engine. Use a light bulb behind the core

in order to inspect the core for cleanliness. Repeat

Radiator - Clean

the cleaning, if necessary.

Inspect the fins for damage. Bent fins may be opened

The radiator is not usually supplied by Perkins. The

with a “comb”. Inspect these items for good condition:

following text describes a typical cleaning procedure

Welds, mounting brackets, air lines, connections,

for the radiator. Refer to the OEM information for

clamps and seals. Make repairs, if necessary.

further information on cleaning the radiator.

i07888480

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

Starting Motor - Inspect

Inspect the radiator for these items: Damaged fins,

corrosion, dirt, grease, insects, leaves, oil and other

debris. Clean the radiator, if necessary.

Perkins recommends a scheduled inspection of the

starting motor. If the starting motor fails, the engine

may not start in an emergency situation.

Check the starting motor for correct operation. Check

the electrical connections and clean the electrical

connections. Refer to the Systems Operation, Testing

and Adjusting Manual, “Electric Starting System -

Test” for more information on the checking procedure

and for specifications consult your Perkins dealer or

your Perkins distributor for assistance.

M0082024-03

143

Maintenance Section

Turbocharger - Inspect

i04922217

Engine Installed with Single

Turbocharger

Turbocharger - Inspect

Hot engine components can cause injury from

burns. Before performing maintenance on the en-

gine, allow the engine and the components to

cool.

NOTICE

Turbocharger bearing failures can cause large quan-

tities of oil to enter the air intake and exhaust sys-

tems. Loss of engine lubricant can result in serious

engine damage.

Minor leakage of oil into a turbocharger under ex-

tended low idle operation should not cause problems

as long as a turbocharger bearing failure has not

occured.

When a turbocharger bearing failure is accompanied

by a significant engine performance loss (exhaust

Illustration 110

g03089297

smoke or engine rpm up at no load), do not continue

engine operation until the turbocharger is renewed.

1. Ensure that the turbocharger is clean and free from

A visual inspection of the turbocharger or

dirt before removing components for inspection.

turbochargers can minimize unscheduled downtime.

2. Remove the pipe from the turbocharger exhaust

A visual inspection of the turbocharger or

turbochargers can also reduce the chance for

outlet and remove the air intake pipe (1). Visually

potential damage to other engine parts. Do not

inspect the piping for the presence of oil. Clean the

inspect the engine with the engine in operation.

interior of the pipes in order to prevent dirt from

entering during reassembly.

3. Check for obvious heat discoloration of the

turbocharger. Check for any loose bolts or any

missing bolts. Check for damage to the oil supply

line and the oil drain line. Check for cracks in the

housing of the turbocharger. Ensure that the

compressor wheel can rotate freely.

4. Check for the presence of oil. If oil is leaking from

the back side of the compressor wheel, there is a

possibility of a failed turbocharger oil seal.

The presence of oil may be the result of extended

engine operation at low idle. The presence of oil

may also be the result of a restriction of the line for

the intake air (clogged air filters), which causes the

turbocharger to slobber.

144

M0082024-03

Maintenance Section

Walk-Around Inspection

5. Install the air intake pipe and the exhaust outlet

4. Check for obvious heat discoloration of the

pipe to the turbocharger housing. Ensure that all

turbocharger. Check for any loose bolts or any

clamps are installed correctly and that all clamps

missing bolts. Check for damage to the oil supply

are tightened securely. For more information, refer

line and the oil drain line. Check for cracks in the

to Systems Operation, Testing, and Adjusting,

housing of the turbocharger. Ensure that the

“Turbocharger - Inspect”.

compressor wheel can rotate freely.

5. Check for the presence of oil. If oil is leaking from

Engine Installed with High

the back side of the compressor wheel, there is a

Pressure Turbocharger and Low

possibility of a failed turbocharger oil seal.

Pressure Turbocharger

The presence of oil may be the result of extended

engine operation at low idle. The presence of oil

may also be the result of a restriction of the line for

the intake air (clogged air filters), which causes the

turbocharger to slobber.

6. Inspect the bore of the housing of the turbine outlet

for corrosion.

7. Install the air intake pipe and the exhaust outlet

pipe to the turbocharger housing. Ensure that all

clamps are installed correctly and that all clamps

are tightened securely. For more information, refer

to Systems Operation, Testing, and Adjusting,

“Turbocharger - Inspect”.

i07676516

Walk-Around Inspection

Inspect the Tube of the Crankcase

Illustration 111

g03089316

Breather

The engine is equipped with a high-pressure

turbocharger (1) and a low-pressure turbocharger

(4). A regular visual inspection of both turbochargers

is recommended. If the turbocharger fails during

engine operation, damage to the turbocharger

compressor wheel and/or to the engine may occur.

Damage to the turbocharger compressor wheel can

damage the pistons, the valves, and the cylinder

head.

1. Ensure that the turbochargers are clean and free

from dirt before removing components for

inspection.

2. Remove the pipe from the high-pressure

turbocharger exhaust outlet and remove the air

intake pipe (3 ) to the turbocharger. Visually

inspect the piping for the presence of oil. Clean the

interior of the pipes in order to prevent dirt from

entering during reassembly.

3. Remove elbow (2) and check for the presence of

engine oil.

Illustration 112

g02351425

Typical example

M0082024-03

145

Maintenance Section

Walk-Around Inspection

Inspect the breather outlet pipe (1) for damage.

• Inspect the piping for the air intake system and the

Ensure that the outlet tip (2) is clean and free from

elbows for cracks and for loose clamps. Ensure

any obstructions. Ice can cause obstructions in

that hoses and tubes are not contacting other

adverse weather conditions.

hoses, tubes, wiring harnesses.

• Ensure that the areas around the rotating parts are

Inspect the Engine for Leaks and

clear.

Loose Connections

• Inspect the alternator belts and any accessory

A walk-around inspection should only take a few

drive belts for cracks, breaks, or other damage.

minutes. When time is taken to perform these

checks, costly repairs and accidents can be avoided.

• Inspect the wiring harness for damage.

For maximum engine service life, make a thorough

Belts for multiple groove pulleys must be replaced as

inspection of the engine compartment before starting

matched sets. If only one belt is replaced, the belt will

the engine. Look for items such as oil leaks or

carry more load than the belts that are not replaced.

coolant leaks, loose bolts, worn belts, loose

The older belts are stretched. The additional load on

connections, and trash buildup. Make repairs, as

the new belt could cause the belt to break.

needed:

• The guards must be in the correct place. Repair

High-Pressure Fuel Lines

damaged guards or replace missing guards.

• Wipe all caps and plugs before the engine is

serviced to reduce the chance of system

Contact with high pressure fuel may cause fluid

contamination.

penetration and burn hazards. High pressure fuel

spray may cause a fire hazard. Failure to follow

NOTICE

these inspection, maintenance and service in-

For any type of leak (coolant, lube, or fuel) clean up

structions may cause personal injury or death.

the fluid. If leaking is observed, find the source and

correct the leak. If leaking is suspected, check the flu-

After the engine has stopped, you must wait for 10

id levels more often than recommended until the leak

minutes to allow the fuel pressure to be purged from

is found or fixed, or until the suspicion of a leak is

the high-pressure fuel lines before any service or

proved to be unwarranted.

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

NOTICE

cooling, lubrication, or air systems. Replace any high-

Accumulated grease and/or oil on an engine is a fire

pressure fuel line that has leaked. Refer to

hazard. Remove the accumulated grease and oil. Re-

Disassembly and Assembly Manual, “Fuel Injection

fer to this Operation and Maintenance Manual, “En-

Lines - Install”.

gine - Clean” for more information.

When there is not an alternative course of action and

the engine must be in operation while it is inspected,

always use the proper inspection procedure to avoid

• Ensure that the cooling system hoses are correctly

a fluid penetration hazard. Refer to Operation and

clamped and that the cooling system hoses are

Maintenance Manual, “General hazard Information”.

tight. Check for leaks. Check the condition of all

pipes.

Visually inspect the high-pressure fuel lines for

damage or signs of fuel leakage. Replace any

• Inspect the water pump for coolant leaks.

damaged high-pressure fuel lines or high-pressure

fuel lines that have leaked.

Note: The water pump seal is lubricated by the

coolant in the cooling system. It is normal for a small

Ensure that all clips on the high-pressure fuel lines

amount of leakage to occur as the engine cools down

are in place and that the clips are not loose.

and parts contract.

• Inspect the rest of the fuel system for leaks. Look

Excessive coolant leakage may indicate the need to

for loose fuel line clamps.

replace the water pump. Remove the water pump.

Refer to Disassembly and Assembly, “Water Pump -

• Drain the water and the sediment from the fuel

Remove and Install”. For more information, consult

tank daily to ensure that only clean fuel enters the

your Perkins dealer or your Perkins distributor.

fuel system.

• Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil

pan, the oil filters, and the rocker cover.

146

M0082024-03

Maintenance Section

Water Pump - Inspect

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed

wires. Check for any loose tie-wraps or missing

tie-wraps.

• Inspect the ground strap for a good connection

and for good condition.

• Disconnect any battery chargers that are not

protected against the current drain of the starting

motor. Check the condition and the electrolyte

level of the batteries, unless the engine is

equipped with a maintenance free battery.

• Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that

cannot be calibrated.

Engine Aftertreatment

Check the condition of the coolant lines, Diesel

Exhaust Fluid (DEF) lines, and electrical

connections. Check that all clamps, clips, and tie-

wraps are secure and in good condition. Check that

the DEF filler cap is secure and that the cap is clean

and free from dirt.

Check the level of DEF in the tank is sufficient for

operational purpose. If necessary fill the tank.

Illustration 113

g01904773

i03570653

(A) Weep hole

(B) Vent hole

Water Pump - Inspect

Note: The water pump seals are lubricated by the

coolant in the cooling system. It is normal for a small

amount of leakage to occur. Refer to illustration 113

A failed water pump may cause severe engine

overheating problems that could result in the

for the position of the weep hole and the vent hole.

following conditions:

Visually inspect the water pump for leaks.

• Cracks in the cylinder head

Note: If engine coolant enters the engine lubricating

system the lubricating oil and the engine oil filter must

• A piston seizure

be replaced. This will remove any contamination that

• Other potential damage to the engine

is caused by the coolant and this will prevent any

irregular oil samples.

The water pump is not a serviceable item. In order to

install a new water pump, refer to the Disassembly

and Assembly Manual, “Water Pump - Remove and

Install”.

M0082024-03

147

Warranty Section

Warranty Information

3. New non-road diesel engines installed in

Warranty Section

construction machines conforming to theSouth

Korean regulations for construction machines

manufactured after January 1, 2015, and operated

Warranty Information

and serviced inSouth Korea, including all parts of

their emission control systems (“emission related

i07304835

components”), are:

Emissions Warranty

a. Designed, built, and equipped so as to conform,

at the time of sale, with applicable emission

Information

standards prescribed in the Enforcement Rule

Mã SMCS: 1000

of the Clean Air Conservation Act promulgated

by South Korea MOE.

The certifying engine manufacturer warrants to the

ultimate purchaser and each subsequent purchaser

b. Free from defects in materials and

that:

workmanship in emission-related components

that can cause the engine to fail to conform to

1. New non-road diesel engines and stationary diesel

applicable emission standards for the warranty

engines less than 10 L per cylinder (including Tier

period.

1 and Tier 2 marine engines < 37 kW, but

excluding locomotive and other marine engines)

The aftertreatment system can be expected to

operated and serviced in the United States and

function properly for the lifetime of the engine

Canada, including all parts of their emission

(emissions durability period) subject to prescribed

control systems (“emission-related components”),

maintenance requirements being followed.

are:

For a detailed explanation of the Emission Control

a. Designed, built, and equipped so as to conform,

Warranty, contact your authorized Perkins dealer or

your authorized Perkins distributor.

at the time of sale, with applicable emission

standards prescribed by the United States

Environmental Protection Agency (EPA) by way

of regulation.

b. Free from defects in materials and

workmanship in emission-related components

that can cause the engine to fail to conform to

applicable emission standards for the warranty

period.

2. New non-road diesel engines (including Tier 1 and

Tier 2 marine propulsion engines < 37 kW and Tier

1 through Tier 4 marine auxiliary engines < 37 kW,

but excluding locomotive and other marine

engines) operated and serviced in the state of

California, including all parts of their emission

control systems (“emission-related components”),

are:

a. Designed, built, and equipped so as to conform,

at the time of sale, to all applicable regulations

adopted by the California Air Resources Board

(ARB).

b. Free from defects in materials and

workmanship which cause the failure of an

emission-related component to be identical in

all material respects to the component as

described in the engine manufacturer's

application for certification for the warranty

period.

148

M0082024-03

Reference Information Section

Reference Materials

• Owners receipts

Reference Information

• Maintenance log

Section

Reference Materials

i05204672

Maintenance Records

Perkins recommends the retention of accurate

maintenance records. Accurate maintenance records

can be used for the following purposes:

• Determine operating costs.

• Establish maintenance schedules for other

engines that are operated in the same

environment.

• Show compliance with the required maintenance

practices and maintenance intervals.

Maintenance records can be used for various other

business decisions that are related to engine

maintenance.

Maintenance records are a key element of a

maintenance program that is correctly managed.

Accurate maintenance records can help your Perkins

dealer to fine-tune the recommended maintenance

intervals in order to meet the specific operating

situation. This should result in a lower engine

operating cost.

Records should be kept for the following items:

Fuel Consumption - A record of fuel consumption is

essential in order to determine when the load

sensitive components should be inspected or

repaired. Fuel consumption also determines overhaul

intervals.

Service Hours - A record of service hours is

essential to determine when the speed sensitive

components should be inspected or repaired.

Documents - These items should be easy to obtain,

and these items should be kept in the engine history

file. All of the documents should show this

information: date, service hours, fuel consumption,

unit number and engine serial number. The following

types of documents should be kept as proof of

maintenance or repair for warranty:

Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of

documents as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owners repair costs

150

M0082024-03

Reference Information Section

Reference Material

i07677995

Reference Material

(Extended Service Contract)

Extended Service Contracts - purchased in minutes,

protected for years.

Extended Service Contracts (ESC) protect you from

the stress that unexpected repair work brings to your

life by covering the cost of getting your engine up and

running again. Unlike other extended warranties,

Perkins Platinum ESC protects you against all

component part failures.

Purchase peace of mind from only £0.03 / $0.05 /

euro 0.04 a day and let an ESC make your dreams a

reality.

Why buy an Extended Service Contract?

1. No surprises - total protection from unexpected

repair cost (parts, labor, and travel).

2. Enjoy longer lasting product support from Perkins

global network.

3. Genuine Perkins parts ensure continued engine

performance.

4. Highly trained technicians carry out all repairs.

5. Transferable coverage should you sell your

machine.

Flexible coverage provides the right level of

protection for your Perkins Engine. Coverage can be

extended to 2 years/ 1,000 hours right up to 10 year/

40,000

You can buy an ESC at any time during standard

warranty - even the last day!

Each Perkins Distributor has highly trained and

experienced Perkins Product Support Service

Technicians. The Support Service is equipped, and

available around the clock to get your engine running

again with the minimum of downtime. Buying an ESC

means that you get all this for free.

To purchase an Extended Service Contract, is quick

and simple! Contact your local Perkins Distributor

now and the distributor can provide you with a quote

in minutes. You can locate your nearest Perkins

Distributor by visiting:

www.perkins.com

NOTICE

Dependant upon engine type and application.

M0082024-03

151

Index Section

Index

Coolant (Commercial Heavy-Duty) -

Change

110

Additional Messages

Drain

110

After Starting Engine

Fill

111

After Stopping Engine

Flush

111

Aftercooler Core - Clean/Test (Air-To-Air

Coolant (ELC) - Change

112

Aftercooler)

107

Drain

112

Aftercooler Core - Inspect

107

Fill

113

Aftertreatment Operation

Flush

113

Alarms and Shutoffs

Coolant Level - Check

116

Alarms

Cooling System Supplemental Coolant

Shutoffs

Additive (SCA) - Test/Add

117

Testing

Add the SCA, If Necessary

117

Alternator - Inspect

107

Test for SCA Concentration

117

Alternator and Fan Belts - Replace

107

Crankshaft Vibration Damper - Inspect

118

Viscous Damper

118

Crushing Prevention and Cutting Prevention.. 18

Battery - Replace

107

Battery Disconnect Switch (If Equipped)

Battery Electrolyte Level - Check

108

DEF Filler Screen (Emission Related

Battery or Battery Cable - Disconnect

108

Component) - Clean

118

Before Starting Engine

20, 64

DEF Manifold Filters (Emission Related

Belt - Inspect

109

Component) - Replace

119

Belt Tensioner - Check

109

Diagnostic Lamp

Burn Prevention

Diesel Exhaust Fluid (Emission Related

Batteries

Component) - Fill

120

Coolant

Diesel Exhaust Fluid Filter (Emission

Diesel Fuel

Related Component) - Replace

121

Engine and Aftertreatment System

Diesel Exhaust Fluid in Cold Weather

Induction System

Diesel Exhaust Fluid Tank - Flush

122

Oils

Driven Equipment - Check

123

Cold Weather Operation

Electrical System

Hints for Cold-Weather Operation

Grounding Practices

Idling the Engine

Emergency Stopping

Recommendations for Coolant Warm Up

Emissions Certification Film

Recommendations for the Coolant

Emissions Warranty Information

147

Viscosity of the Engine Lubrication Oil

Engaging the Driven Equipment

Cold Weather Starting

Engine - Clean

123

Configuration Parameters

Aftertreatment

123

Customer Specified Parameters

Engine Air Cleaner Element - Replace

123

System Configuration Parameters

Servicing the Air Cleaner Element

124

Coolant - Change

114

Engine Air Cleaner Service Indicator -

Drain

114

Inspect

124

Fill

116

Test the Service Indicator

125

Flush

115

Engine Air Precleaner - Check/Clean

125

152

M0082024-03

Index Section

Engine Crankcase Breather Element

Contamination Control Recommendations for

(Emission Related Component) - Replace

Fuels

(Type 1)

127

Diesel Fuel Characteristics

Bottom Service

129

Diesel Fuel Requirements

Check the System

130

General Information

Top Service

127

Foreword

Engine Crankcase Breather Element

California Proposition 65 Warning

(Emission Related Component) - Replace

Literature Information

(Type 2)

125

Maintenance

Check the System

127

Maintenance Intervals

Engine Diagnostics

Operation

Engine Electronics

Overhaul

Engine Mounts - Inspect

130

Safety

Engine Oil and Filter - Change

131

Fuel and the Effect from Cold Weather

Drain the Engine Lubricating Oil

132

Fuel Conservation Practices

Fill the Oil Pan

133

Fuel Filter (In-Line) - Replace

134

Oil and Filter Change Intervals

131

Fuel Related Components in Cold Weather ... 80

Replace the Oil Filter

132

Fuel Filters

Engine Oil Level - Check

130

Fuel Heaters

Engine Oil Sample - Obtain

131

Fuel Tanks

Obtain the Sample and the Analysis

131

Fuel System - Prime

135

Engine Operation

Fuel System Primary Filter (Water

Carbon Dioxide (CO2) Emissions

Separator) Element - Replace

136

Engine Operation and the Aftertreatment

Install the New Filter Element

137

System

Remove the Element

136

Engine Operation with Active Diagnostic

Fuel System Primary Filter/Water

Codes

Separator - Drain

138

Engine Operation with Intermittent

Drain Procedure

138

Diagnostic Codes

Fuel System Secondary Filter - Replace

138

Engine Starting

20, 64

Install the Element

139

Engine Stopping

21, 82

Remove the Element

139

Fuel Tank Water and Sediment - Drain

140

Drain the Water and the Sediment

140

Fuel Storage Tanks

140

Fan Clearance - Check

133

Fuel Tank

140

Fault Logging

Features and Controls

Fire Prevention and Explosion Prevention

Ether

Gauges and Indicators

Fire Extinguisher

Aftertreatment Lamps and gauges

Lines, Tubes, and Hoses

Indicator Lamps

Fluid Recommendations

94, 99

General Hazard Information

ELC Cooling System Maintenance

Containing Fluid Spillage

Engine Oil

Diesel Exhaust Fluid

General Coolant Information

Dispose of Waste Properly

General Lubricant Information

Fluid Penetration

Fluid Recommendations (Diesel Exhaust

Inhalation

Fluid (DEF))

Pressurized Air and Water

General Information

Static Electricity Hazard when Fueling with

Fluid Recommendations (General Fuel

Ultra-low Sulfur Diesel Fuel

Information)

General Information

M0082024-03

153

Index Section

Overspeed

High Pressure Fuel Lines

Hoses and Clamps - Inspect/Replace

140

Replace the Hoses and the Clamps

141

Plate Locations and Film Locations

Serial Number Plate (1)

Plate Locations and Film Locations

(Aftertreatment System)

Important Safety Information

Clean Emissions Module (CEM)

Injector (Diesel Exhaust Fluid) (Emissions

Pump Tank Unit (PTU)

Related Component) - Replace

141

Product Description (Engine and

Aftertreatment)

Aftermarket Products and Perkins

Engines

Lifting and Storage

Aftertreatment System

Electronic Engine Features

Engine Cooling and Lubrication

Maintenance Interval Schedule

105

Engine Diagnostics

Daily

105

Engine Service Life

Every 10 000 Service Hours

106

Engine Specifications

Every 1000 Service Hours

105

Product Identification Information

Every 1500 Service Hours

105

Product Information Section

Every 2000 Service Hours

105

Product Lifting

Every 3000 Service Hours

105

Engine and Clean Emissions Module

Every 3000 Service Hours or 1 Year

105

(CEM)

Every 3000 Service Hours or 2 Years

105

Engine CEM and Radiator

Every 4000 Service Hours

105

Product Storage (Engine and

Every 4500 Service Hours

105

Aftertreatment)

Every 50 Service Hours or Weekly

105

Aftertreatment

Every 500 Service Hours

105

Condition for Storage

Every 500 Service Hours or 1 Year

105

Every 5000 Service Hours

105

Every 6000 Service Hours or 3 Years

106

When Required

105

Radiator - Clean

142

Maintenance Log

149

Radiator Restrictions

Maintenance Recommendations

102

Reference Information

Record for Reference

Maintenance Records

148

Reference Information Section

148

Maintenance Section

Model View Illustrations

Reference Material (Extended Service

Aftertreatment Systems

Contract)

150

Off Engine Components

Reference Materials

148

Pump Tank Unit (PTU)

Refill Capacities

Cooling System

Series Turbocharged Engine

Lubrication System

Single Turbocharged Engine

Monitoring System (Engine Indicators and

Aftertreatment Indicators)

Engine Indicator Lamps

Safety Messages

Mounting and Dismounting

Ether Warning 2

Hand (High Pressure) 3

Universal Warning 1

Operation Section

Safety Section

154

M0082024-03

Index Section

Selective Catalytic Reduction Warning

System

Warning Indicators

Warning Levels

Warning Strategy

Self-Diagnostics

Sensors and Electrical Components

Aftertreatment Components

Engine Components

Severe Service Application

104

Environmental Factors

104

Incorrect Maintenance Procedures

104

Incorrect Operating Procedures

104

Starting Motor - Inspect

142

Starting the Engine

Starting with Jump Start Cables (Do Not

Use This Procedure in Hazardous

Locations that have Explosive

Atmospheres)

Stopping the Engine

System Pressure Release

102

Coolant System

102

Engine Oil

102

Fuel System

102

Table of Contents

Turbocharger - Inspect

143

Engine Installed with High Pressure

Turbocharger and Low Pressure

Turbocharger

144

Engine Installed with Single

Turbocharger

143

Walk-Around Inspection

144

Engine Aftertreatment

146

High-Pressure Fuel Lines

145

Inspect the Engine for Leaks and Loose

Connections

145

Inspect the Tube of the Crankcase

Breather

144

Warranty Information

147

Warranty Section

147

Water Pump - Inspect

146

Welding on Engines with Electronic

Controls

102

Perkins 1206J-E70TA and 1206J-E70TTA Industrial Engines. Operation Manual (2021) - page 4