Title: Perkins Operators Manual Author: Perkins Engines Subject: 4.108, 4.154, 4.236 Created Date: 2/22/2007 4:00:40 PM.
SEBU8311-01 April 2008 Operation and Maintenance Manual 402D-403D-404D Industrial Engine GG (Engine) GH (Engine) GJ (Engine) GK (Engine) GL (Engine) GM (Engine).
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Operation and Maintenance Manual
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SEBU8311-01 April 2008 Operation and Maintenance Manual 402D-403D-404D Industrial Engine GG (Engine) GH (Engine) GJ (Engine) GK (Engine) GL (Engine) GM (Engine) GN (Engine) GP (Engine) GQ (Engine) GS (Engine) This document has been printed from SPIČ. Not for Resale Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available. When replacement parts are required for this product Perkins recommends using Perkins replacement parts. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. This document has been printed from SPIČ. Not for Resale SEBU8311-01 3 Table of Contents Table of Contents Foreword ................................................................. 4 Safety Section Safety Messages .................................................... 5 General Hazard Information ................................... 7 Burn Prevention ...................................................... 8 Fire Prevention and Explosion Prevention .............. 8 Crushing Prevention and Cutting Prevention ........ 10 Before Starting Engine ........................................... 11 Engine Starting ...................................................... 11 Engine Stopping .................................................... 11 Electrical System .................................................. 12 Product Information Section Model Views ......................................................... 13 Product Identication Information ........................ 23 Operation Section Lifting and Storage ................................................ 25 Gauges and Indicators .......................................... 28 Features and Controls .......................................... 29 Engine Starting ..................................................... 30 Engine Operation .................................................. 33 Engine Stopping ................................................... 34 Cold Weather Operation ....................................... 35 Maintenance Section Rell Capacities .................................................... 39 Maintenance Interval Schedule ............................ 58 Warranty Section Warranty Information ............................................ 89 Index Section Index ..................................................................... 90 This document has been printed from SPIČ. Not for Resale 4 Foreword SEBU8311-01 Foreword Literature Information This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information. English is the primary language for all Perkins publications. The English used facilitates translation and consistency. Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Perkins dealer or your Perkins distributor for the latest available information. Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specied in the Maintenance Interval Schedule may be necessary. The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures. Maintenance Intervals Perform maintenance on items at multiples of the original requirement. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine’s permanent record. Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment. Safety This safety section lists basic safety precautions. In addition, this section identies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product. Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your Perkins distributor offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options. Operation Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efciently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities. The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information. California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. Maintenance The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow. This document has been printed from SPIČ. Not for Resale SEBU8311-01 5 Safety Section Safety Messages Safety Section i02959960 Warning label (A) is installed in different locations. The location will change according to the physical size of the engine. Safety Messages There may be several specic warning signs on your engine. The exact location and a description of the warning signs are reviewed in this section. Please become familiar with all warning signs. Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning signs. The warning signs that are loosened could drop off of the engine. Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Perkins dealer or your distributor can provide new warning signs. (A) Universal Warning Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death. Illustration 1 Typical example g01154807 This document has been printed from SPIČ. Not for Resale 6 Safety Section Safety Messages SEBU8311-01 Illustration 2 (A) Location of warning label (1) 402D-05 (2) 403D-07 (3) 403D-11 (4) 403D-15, 403D-15T and 403D-17 (5) 404D-15 g01324126 (6) 404D-22, 404D-22T and 404D-22TA This document has been printed from SPIČ. Not for Resale SEBU8311-01 7 Safety Section General Hazard Information i02328435 Report all necessary repairs. Do not allow unauthorized personnel on the equipment. Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs. Perform maintenance on the engine with the equipment in the servicing position. Refer to the OEM information for the procedure for placing the equipment in the servicing position. General Hazard Information Pressure Air and Water Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury. Illustration 3 g00104545 Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment. The direct application of pressurized air or pressurized water to the body could result in personal injury. When pressurized air and/or water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic uid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly. Illustration 4 g00702020 Wear a hard hat, protective glasses, and other protective equipment, as required. Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. Make sure that all protective guards and all covers are secured in place on the engine. Keep the engine free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps. Never put maintenance uids into glass containers. Drain all liquids into a suitable container. Obey all local regulations for the disposal of liquids. Use all cleaning solutions with care. Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure. This document has been printed from SPIČ. Not for Resale 8 Safety Section Burn Prevention SEBU8311-01 Coolant When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. Check the coolant level after the engine has stopped and the engine has been allowed to cool. Illustration 5 g00687600 Always use a board or cardboard when you check for a leak. Leaking uid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If uid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury. Ensure that the ller cap is cool before removing the ller cap. The ller cap must be cool enough to touch with a bare hand. Remove the ller cap slowly in order to relieve pressure. Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth. Oils Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin. Containing Fluid Spillage Care must be taken in order to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Make provision to collect the uid with a suitable container before any compartment is opened or before any component is disassembled. Batteries Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended. i02813488 • Only use the tools that are suitable for collecting uids and equipment that is suitable for collecting uids. uids and equipment that is suitable for containing uids. • Only use the tools that are suitable for containing Obey all local regulations for the disposal of liquids. i02143195 Fire Prevention and Explosion Prevention Burn Prevention Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the air system, in the hydraulic system, in the lubrication system, in the fuel system, or in the cooling system before any lines, ttings or related items are disconnected. Illustration 6 g00704000 This document has been printed from SPIČ. Not for Resale SEBU8311-01 9 Safety Section Fire Prevention and Explosion Prevention All fuels, most lubricants, and some coolant mixtures are ammable. Flammable uids that are leaking or spilled onto hot surfaces or onto electrical components can cause a re. Fire may cause personal injury and property damage. A ash re may result if the covers for the engine crankcase are removed within fteen minutes after an emergency shutdown. Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result. If the application involves the presence of combustible gases, consult your Perkins dealer and/or your Perkins distributor for additional information about suitable protection devices. Remove all ammable combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any ammable combustible materials or conductive materials to accumulate on the engine. Store fuels and lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any ammable materials in protective containers. Do not smoke in areas that are used for storing ammable materials. Do not expose the engine to any ame. Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed correctly. Do not weld on lines or tanks that contain ammable uids. Do not ame cut lines or tanks that contain ammable uid. Clean any such lines or tanks thoroughly with a nonammable solvent prior to welding or ame cutting. Wiring must be kept in good condition. All electrical wires must be correctly routed and securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections. Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers. Arcing or sparking could cause a re. Secure connections, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking. Inspect all lines and hoses for wear or for deterioration. The hoses must be correctly routed. The lines and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause res. Oil lters and fuel lters must be correctly installed. The lter housings must be tightened to the correct torque. Illustration 7 g00704059 Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open ames or sparks. Always stop the engine before refueling. This document has been printed from SPIČ. Not for Resale 10 Safety Section Crushing Prevention and Cutting Prevention SEBU8311-01 Repair any lines that are loose or damaged. Leaks can cause res. Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque. Replace the parts if any of the following conditions are present: • End ttings are damaged or leaking. • Outer coverings are chafed or cut. • Wires are exposed. • Outer coverings are ballooning. Illustration 8 g00704135 • Flexible part of the hoses are kinked. • Outer covers have embedded armoring. • End ttings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other parts, and excessive heat. i02143194 Gases from a battery can explode. Keep any open ames or sparks away from the top of a battery. Do not smoke in battery charging areas. Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer. Incorrect jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specic instructions. Do not charge a frozen battery. This may cause an explosion. The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated. Crushing Prevention and Cutting Prevention Support the component correctly when work beneath the component is performed. Unless other maintenance instructions are provided, never attempt adjustments while the engine is running. Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstall the guards. Keep objects away from moving fan blades. The fan blades will throw objects or cut objects. When objects are struck, wear protective glasses in order to avoid injury to the eyes. Chips or other debris may y off objects when objects are struck. Before objects are struck, ensure that no one will be injured by ying debris. Fire Extinguisher Make sure that a re extinguisher is available. Be familiar with the operation of the re extinguisher. Inspect the re extinguisher and service the re extinguisher regularly. Obey the recommendations on the instruction plate. Lines, Tubes and Hoses Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. Do not clip any other items to the high pressure lines. This document has been printed from SPIČ. Not for Resale SEBU8311-01 11 Safety Section Before Starting Engine i02813489 Before Starting Engine Before the initial start-up of an engine that is new, serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine. Overspeed shutdown should occur automatically for engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop button in order to cut the fuel and/or air to the engine. Inspect the engine for potential hazards. Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel. If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work correctly, if equipped. All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully. Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage. See the Service Manual for repairs and for adjustments. i02157354 All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully. Start the engine from the operator’s compartment or from the engine start switch. Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing the correct procedure will help to prevent major damage to the engine components. Knowing the procedure will also help to prevent personal injury. To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working correctly, check the water temperature gauge and the oil temperature gauge during the heater operation. Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside. Note: The engine is equipped with an automatic device for cold starting for normal conditions of operation. If the engine will be operated in very cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation. The 400 Series engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting. i02590389 Engine Stopping To avoid overheating of the engine and accelerated wear of the engine components, stop the engine according to this Operation and Maintenance Manual, “Engine Stopping” topic (Operation Section). Engine Starting Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. If a warning tag is attached to the engine start switch or to the controls, DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started. Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. DO NOT use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected. This document has been printed from SPIČ. Not for Resale 12 Safety Section Electrical System SEBU8311-01 On the initial start-up of a new engine or an engine that has been serviced, make provisions to stop the engine if an overspeed condition occurs. This may be accomplished by shutting off the fuel supply and/or the air supply to the engine. If equipped, in order to stop an electronically controlled engine, cut the power to the engine. i02176668 Electrical System Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite. To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” jump start cable should be connected last from the external power source to the negative “−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the jump start cable to the engine block. Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specic starting instructions. Grounding Practices Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability. Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths. Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components. Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge. To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This path may be provided by way of a direct engine ground to the frame. All grounds should be tight and free of corrosion. The engine alternator must be grounded to the negative “-” battery terminal with a wire that is adequate to handle the full charging current of the alternator. This document has been printed from SPIČ. Not for Resale SEBU8311-01 13 Product Information Section Model Views Product Information Section Model Views i02590436 Model View Illustrations The following model views show typical features of the 400 series engines. Due to individual applications, your engine may appear different from the illustrations. Note: Individual components are detailed on the 404D-22T turbocharged engine only. Illustration 9 Typical view of the 402D-05 engine g01299985 This document has been printed from SPIČ. Not for Resale 14 Product Information Section Model Views SEBU8311-01 Illustration 10 Typical view of the 403D-15T engine g01300431 This document has been printed from SPIČ. Not for Resale SEBU8311-01 15 Product Information Section Model Views Illustration 11 Front and right side view of the 404D-22T Engine (1) (2) (3) (4) Fuel shutoff solenoid Number one fuel injector Water pump Lower engine oil ller cap (5) Throttle lever (6) Cover plate for the accessory drive (7) Engine oil level gauge (8) Engine oil cooler (9) Engine oil lter (10) Fuel injection pump (11) Transfer pump (12) Fuel lter g01304893 This document has been printed from SPIČ. Not for Resale 16 Product Information Section Model Views SEBU8311-01 Illustration 12 Front and left side view of the 404D-22T Engine (13) (14) (15) (16) (17) (18) Top engine oil ller cap Crankcase breather Rear Lifting eye Air inlet elbow Valve mechanism cover Turbocharger (19) Water temperature regulator housing (20) Starting motor solenoid (21) Electric starting motor (22) Alternator (23) Engine oil pan (24) Engine oil drain plug (25) (26) (27) (28) Fan drive belt Crankshaft pulley Coolant temperature switch Cooling fan g01305224 i02959055 Engine Description The 400 series engines are indirect injection engines. The engines are controlled with a mechanically actuated fuel injection pump. The engine cylinders are arranged in-line. The cylinder head assembly has one inlet valve and one exhaust valve for each cylinder. Each cylinder valve has a single valve spring. The pistons have two compression rings and an oil control ring. It is important to ensure the correct piston height so that the piston does not contact the cylinder head. The correct piston height also ensures efcient combustion of fuel that is necessary in order to conform to requirements for emissions. The crankshaft for a two cylinder engine has two main bearing journals. The crankshaft for a three cylinder engine has four main bearing journals. The crankshaft for a four cylinder engine has ve main bearing journals. End play is controlled by the thrust washers that are located on the rear main bearing. This document has been printed from SPIČ. Not for Resale SEBU8311-01 17 Product Information Section Model Views The timing gears are stamped with timing marks in order to ensure the correct assembly of the gears. When the No. 1 piston is at top center compression stroke, the teeth that are stamped on the crankshaft gear and the camshaft gear will be in alignment with the idler gear. The crankshaft gear turns the idler gear which then turns the camshaft gear and the gear for the engine oil pump. The fuel injection pump is mounted in the cylinder block. The fuel injection pump is operated by lobes on the camshaft. The fuel transfer pump is located on the right hand side of the cylinder block. The fuel transfer pump is also operated by lobes on the camshaft. The fuel injection pump conforms to requirements for emissions. If any adjustments to the fuel injection pump timing and high idle are required you must refer to your Perkins distributoror your Perkins dealer. Some fuel injection pumps have mechanical governors that control the engine rpm. Some fuel injection pumps have a governor that is electrically controlled. A gerotor oil pump is located in the center of the idler gear. The engine oil pump sends lubricating oil to the main oil gallery through a pressure relief valve and an engine oil lter. The rocker arms receive pressurized oil through an externally located oil line that runs from the main oil gallery to the cylinder head. Coolant from the bottom of the radiator passes through the belt driven centrifugal water pump. The coolant is cooled by the radiator and the temperature is regulated by a water temperature regulator. Engine efciency, efciency of emission controls, and engine performance depend on adherence to correct operation and maintenance recommendations. Engine performance and efciency also depend on the use of recommended fuels, lubrication oils, and coolants. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information on maintenance items. Engine Specications Note: The front end of the engine is opposite the ywheel end of the engine. The left and the right side of the engine are determined from the ywheel end. The No. 1 cylinder is the front cylinder. This document has been printed from SPIČ. Not for Resale 18 Product Information Section Model Views SEBU8311-01 402D-05 Engine 403D-07 Engine Illustration 13 (A) Exhaust valves (B) Inlet valves Table 1 g01108476 Illustration 14 (A) Exhaust valves (B) Inlet valves Table 2 g00852304 402D-05 Engine Specications Maximum Operating Speed (rpm) Cylinders and Arrangement Bore Stroke Displacement Aspiration Compression Ratio Firing Order Rotation that is viewed from the ywheel Valve Lash Setting (Inlet) Valve Lash Setting (Exhaust) Injection (1) 403D-07 Engine Specications Maximum Operating Speed (rpm) Cylinders and Arrangement Bore Stroke Displacement Aspiration Compression Ratio Firing Order Rotation that is viewed from the ywheel Valve Lash Setting (Inlet) Valve Lash Setting (Exhaust) Injection (1) 3600 rpm In-Line two cylinder 67 mm (2.64 inch) 72 mm (2.83 inch) 0.507 L (30.939 in ) 3 3600 rpm In-Line three cylinder 67 mm (2.64 inch) 72 mm (2.83 inch) 0.762 L (46.500 in3) NA(1) 23.5:1 1-2-3 Counterclockwise 0.20 mm (0.008 inch) 0.20 mm (0.008 inch) Indirect NA(1) 23.5:1 1-2 Counterclockwise 0.20 mm (0.008 inch) 0.20 mm (0.008 inch) Indirect Naturally Aspirated Naturally Aspirated This document has been printed from SPIČ. Not for Resale SEBU8311-01 19 Product Information Section Model Views 403D-11 Engine 403D-15 Engine Illustration 15 (A) Exhaust valves (B) Inlet valves Table 3 g00852304 Illustration 16 (A) Exhaust valves (B) Inlet valves Table 4 g00852304 403D-11 Engine Specications Maximum Operating Speed (rpm) Cylinders and Arrangement Bore Stroke Displacement Aspiration Compression Ratio Firing Order Rotation that is viewed from the ywheel Valve Lash Setting (Inlet) Valve Lash Setting (Exhaust) Injection (1) 403D-15 Engine Specications Maximum Operating Speed (rpm) Cylinders and Arrangement Bore Stroke Displacement Aspiration Compression Ratio Firing Order Rotation that is viewed from the ywheel Valve Lash Setting (Inlet) Valve Lash Setting (Exhaust) Injection (1) 3600 rpm In-Line three cylinder 77 mm (3.03 inch) 81 mm (3.19 inch) 1.131 L (69.018 in ) 3 3000 rpm In-Line three cylinder 84 mm (3.31 inch) 90 mm (3.54 inch) 1.496 L (91.291 in3) NA(1) 22.5:1 1-2-3 Counterclockwise 0.20 mm (0.008 inch) 0.20 mm (0.008 inch) Indirect NA(1) 23:1 1-2-3 Counterclockwise 0.20 mm (0.008 inch) 0.20 mm (0.008 inch) Indirect Naturally Aspirated Naturally Aspirated This document has been printed from SPIČ. Not for Resale 20 Product Information Section Model Views SEBU8311-01 403D-15T Engine 403D-17 Engine Illustration 17 (A) Exhaust valves (B) Inlet valves Table 5 g00852304 Illustration 18 (A) Exhaust valves (B) Inlet valves Table 6 g00852304 403D-15T Engine Specications Maximum Operating Speed (rpm) Cylinders and Arrangement Bore Stroke Displacement Aspiration Compression Ratio Firing Order Rotation that is viewed from the ywheel Valve Lash Setting (Inlet) Valve Lash Setting (Exhaust) Injection (1) 403D-17 Engine Specications Maximum Operating Speed (rpm) Cylinders and Arrangement Bore Stroke Displacement Aspiration Compression Ratio Firing Order Rotation that is viewed from the ywheel Valve Lash Setting (Inlet) Valve Lash Setting (Exhaust) Injection (1) 3000 rpm In-Line three cylinder 84 mm (3.31 inch) 90 mm (3.54 inch) 1.496 L (91.291 in ) 3 2600 rpm In-Line three cylinder 84 mm (3.31 inch) 100 mm (3.94 inch) 1.66 L (101.3 in3) NA(1) 23.1:1 1-2-3 Counterclockwise 0.20 mm (0.008 inch) 0.20 mm (0.008 inch) Indirect T(1) 22.5:1 1-2-3 Counterclockwise 0.20 mm (0.008 inch) 0.20 mm (0.008 inch) Indirect Turbocharged Naturally Aspirated This document has been printed from SPIČ. Not for Resale SEBU8311-01 21 Product Information Section Model Views 404D-15 Engine 404D-22 Engine Illustration 19 (A) Exhaust valves (B) Inlet valves Table 7 g00296424 Illustration 20 (A) Exhaust valves (B) Inlet valves Table 8 g00296424 404D-15 Engine Specications Maximum Operating Speed (rpm) Cylinders and Arrangement Bore Stroke Displacement Aspiration Compression Ratio Firing Order Rotation that is viewed from the ywheel Valve Lash Setting (Inlet) Valve Lash Setting (Exhaust) Injection (1) 404D-22 Engine Specications Maximum Operating Speed (rpm) Cylinders and Arrangement Bore Stroke Displacement Aspiration Compression Ratio Firing Order Rotation that is viewed from the ywheel Valve Lash Setting (Inlet) Valve Lash Setting (Exhaust) Injection (1) 3000 rpm In-Line four cylinder 77 mm (3.03 inch) 81 mm (3.19 inch) 1.508 L (92.024 in ) 3 3000 rpm In-Line four cylinder 84.0 mm (3.31 inch) 100.0 mm (3.94 inch) 2.216 L (135.229 in3) NA(1) 23.3:1 1-3-4-2 Counterclockwise 0.20 mm (0.008 inch) 0.20 mm (0.008 inch) Indirect NA(1) 23.5:1 1-3-4-2 Counterclockwise 0.20 mm (0.008 inch) 0.20 mm (0.008 inch) Indirect Naturally Aspirated Naturally Aspirated This document has been printed from SPIČ. Not for Resale 22 Product Information Section Model Views SEBU8311-01 404D-22T Engine 404D-22TA Engine Illustration 21 (A) Exhaust valves (B) Inlet valves Table 9 g00296424 Illustration 22 (A) Exhaust valves (B) Inlet valves Table 10 g00296424 404D-22T Engine Specications Maximum Operating Speed (rpm) Cylinders and Arrangement Bore Stroke Displacement Aspiration Compression Ratio Firing Order Rotation that is viewed from the ywheel Valve Lash Setting (Inlet) Valve Lash Setting (Exhaust) Injection (1) 404D-22TA Engine Specications Maximum Operating Speed (rpm) Cylinders and Arrangement Bore Stroke Displacement Aspiration Compression Ratio Firing Order Rotation that is viewed from the ywheel Valve Lash Setting (Inlet) Valve Lash Setting (Exhaust) Injection (1) 3000 rpm In-Line four cylinder 84.0 mm (3.31 inch) 100.0 mm (3.94 inch) 2.216 L (135.229 in ) 3 2800 rpm In-Line four cylinder 84.0 mm (3.31 inch) 100.0 mm (3.94 inch) 2.216 L (135.229 in3) TA(1) 23.5:1 1-3-4-2 Counterclockwise 0.20 mm (0.008 inch) 0.20 mm (0.008 inch) Indirect T(1) 23.5:1 1-3-4-2 Counterclockwise 0.20 mm (0.008 inch) 0.20 mm (0.008 inch) Indirect Turbocharged Turbocharged aftercooled This document has been printed from SPIČ. Not for Resale SEBU8311-01 23 Product Information Section Product Identication Information Product Identication Information i02643641 The following information is stamped on the Serial Number Plate: Engine serial number, Model, and Arrangement number. i02164876 Engine Identication Perkins engines are identied by a serial number. This number is shown on a serial number plate that is mounted above the fuel injection pump on the right hand side of the engine block. An example of an engine number is GP*****U000001M. GP _________ ________________________________Type of engine ___________________Built in the United Kingdom U _________ _____________ The list number of the engine *****_________ __________________ Engine Serial Number 000001 _________ ___________________________Year of Manufacture M _________ Reference Numbers Information for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Make a copy of this list for a record. Keep the information for future reference. Record for Reference Engine Model _________ ______________________________________ Engine Serial number _________ ____________________________ Engine Low Idle rpm _________ _____________________________ Engine Full Load rpm _________ ____________________________ Primary Fuel Filter _________ ________________________________ Water Separator Element _________ _______________________ Secondary Fuel Filter Element _________ _________________ Lubrication Oil Filter Element _________ __________________ i02157258 Perkins dealers or Perkins distributors need all of these numbers in order to determine the components that were included with the engine. This permits accurate identication of replacement part numbers. Serial Number Plate Auxiliary Oil Filter Element _________ ______________________ Total Lubrication System Capacity _________ ____________ Total Cooling System Capacity _________ ________________ Air Cleaner Element _________ ______________________________ Fan Drive Belt _________ _____________________________________ Alternator Belt _________ _____________________________________ Illustration 23 Typical serial number plate g01094203 The Serial Number Plate is located above the fuel injection pump on the right side of the cylinder block. This document has been printed from SPIČ. Not for Resale 24 Product Information Section Product Identication Information SEBU8311-01 i02959144 Emissions Certication Film Illustration 24 Typical example g01478138 Illustration 25 Typical example g01476654 Perkins Shibaura Engines Limited will supply the fuel label with every engine. Refer to illustration 25. The equipment manufacturer must install the label to the equipment. This is recommended by Perkins Shibaura Engines Limited. The label must be attached to the equipment near the fuel inlet. This will comply with the EPA regulations. The equipment manufacturer may install another fuel label. If another fuel label is used, the equipment manufacturer must send a drawing or a photo of the label to Perkins Shibaura Engines Limited through the Perkins Distributor. This will ensure compliance of the label. This document has been printed from SPIČ. Not for Resale SEBU8311-01 25 Operation Section Lifting and Storage Operation Section Lifting and Storage i02164186 Some removals require lifting the xtures in order to obtain correct balance and safety. To remove the engine ONLY, use the lifting eyes that are on the engine. Lifting eyes are designed and installed for specic engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting xtures obsolete. If alterations are made, ensure that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information regarding xtures for correct engine lifting. i02593735 Engine Lifting Engine Storage If the engine will not be started for several weeks, the lubricating oil will drain from the cylinder walls and from the piston rings. Rust can form on the cylinder walls. Rust on the cylinder walls will cause increased engine wear and a reduction in engine service life. Lubrication System To help prevent excessive engine wear, use the following guidelines: Complete all of the lubrication recommendations that are listed in this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section). If an engine is out of operation and if use of the engine is not planned, special precautions should be made. If the engine will be stored for more than one month, a complete protection procedure is recommended. Use the following guidelines : Illustration 26 g01097527 NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight. Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted. • Completely clean the outside of the engine. • Drain the fuel system completely and rell the system with preservative fuel. 1772204 POWERPART Lay-Up 1 can be mixed with the normal fuel in order to change the fuel into preservative fuel. • If preservative fuel is not available, the fuel system can be lled with normal fuel. This fuel must be discarded at the end of the storage period together with the fuel lter elements. operating temperature. Stop any leaks from fuel, lubricating oil or air systems. Stop the engine and drain the lubricating oil from the oil pan. • Operate the engine until the engine reaches normal This document has been printed from SPIČ. Not for Resale 26 Operation Section Lifting and Storage SEBU8311-01 • Renew the canister(s) of the lubricating oil lter. • Fill the oil pan to the Full Mark on the engine oil level gauge with new, clean lubricating oil. Add 1762811 POWERPART Lay-Up 2 to the oil in order to protect the engine against corrosion. If 1762811 POWERPART Lay-Up 2 is not available, use a preservative of the correct specication instead of the lubricating oil. If a preservative is used, this must be drained completely at the end of the storage period and the oil pan must be relled to the correct level with normal lubricating oil. 1. Ensure that the vehicle is on level ground. 2. Remove the ller cap of the cooling system. 3. Remove the drain plug (1) from the side of the cylinder block in order to drain the engine. Ensure that the drain hole is not restricted. 4. Open the tap or remove the drain plug at the bottom of the radiator in order to drain the radiator. If the radiator does not have a tap or a drain plug, disconnect the hose at the bottom of the radiator. 5. Flush the cooling system with clean water. 6. Fit the drain plugs and the ller cap. Close the tap or connect the radiator hose. 7. Fill the cooling system with an approved antifreeze mixture because this gives protection against corrosion. Note: Certain corrosion inhibitors could cause damage to some engine components. Contact the Service Department of Perkins for advice. 8. Operate the engine for a short period in order to circulate the lubricating oil and the coolant in the engine. 9. Disconnect the battery. Put the battery into safe storage in a fully charged condition. Before the battery is put into storage, protect the terminals against corrosion. 1734115 POWERPART Lay-Up 3 can be used on the terminals. 10. Clean the crankcase breather if one is installed. Seal the end of the pipe. 11. Remove the fuel injectors and spray 1762811 POWERPART Lay-Up 2 for one or two seconds into each cylinder bore with the piston at BDC. 12. Slowly rotate the crankshaft for one complete revolution and then replace the fuel injectors. Cooling System To help prevent excessive engine wear, use the following guidelines: NOTICE Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged. If freezing temperatures are expected, check the cooling system for adequate protection against freezing. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” (Maintenance Section). NOTICE To prevent frost damage, ensure that all the coolant is removed from the engine. This is important if the system is drained after it has been ushed with water, or if an antifreeze solution too weak to protect the system from frost has been used. Induction System • Remove the air lter assembly. If necessary, remove the pipes that are installed between the air lter assembly and the turbocharger. Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spray is printed on the container. Seal the turbocharger with waterproof tape. Illustration 27 Typical example g01298045 This document has been printed from SPIČ. Not for Resale SEBU8311-01 27 Operation Section Lifting and Storage Exhaust System • Remove the exhaust pipe. Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spray is printed on the container. Seal the turbocharger with waterproof tape. General Items • If the lubricating oil ller is installed on the valve mechanism cover, remove the ller cap. If the lubricating oil ller cap is not installed on the valve mechanism cover, remove the valve mechanism cover. Spray 1762811 POWERPART Lay-Up 2 around the rocker shaft assembly. Replace the ller cap or the valve mechanism cover. with waterproof tape. belts into storage. • Seal the vent of the fuel tank or the fuel ller cap • Remove the alternator drive belts and put the drive • In order to prevent corrosion, spray the engine with 1734115 POWERPART Lay-Up 3. Do not spray the area inside the alternator. When the engine protection has been completed in accordance with these instructions, this ensures that no corrosion will occur. Perkins are not responsible for damage which may occur when an engine is in storage after a period in service. Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods. This document has been printed from SPIČ. Not for Resale 28 Operation Section Gauges and Indicators SEBU8311-01 Gauges and Indicators i02216960 1. Reduce the load and the engine rpm. 2. Inspect the cooling system for leaks. Gauges and Indicators Your engine may not have the same gauges or all of the gauges that are described. For more information about the gauge package, see the OEM information. Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine the normal operating range by observing the gauges over a period of time. Noticeable changes in gauge readings indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specications. Determine and correct the cause of any signicant change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance. NOTICE If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine. Engine damage can result. Engine Oil Pressure – The oil pressure should be greatest after a cold engine is started. The typical engine oil pressure with SAE10W30 is 207 to 413 kPa (30 to 60 psi) at rated rpm. A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, perform the following procedure: 1. Remove the load. 2. Reduce engine speed to low idle. 3. Check and maintain the oil level. Jacket Water Coolant Temperature – Typical temperature range is 71 to 96°C (160 to 205°F). The maximum allowable temperature with the pressurized cooling system at 90 kPa (13 psi) is 110°C (230°F). Higher temperatures may occur under certain conditions. The water temperature reading may vary according to load. The reading should never exceed the boiling point for the pressurized system that is being used. If the engine is operating above the normal range and steam becomes apparent, perform the following procedure: 3. Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load. Tachometer – This gauge indicates engine speed (rpm). When the throttle control lever is moved to the full throttle position without load, the engine is running at high idle. The engine is running at the full load rpm when the throttle control lever is at the full throttle position with maximum rated load. NOTICE To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. The engine can be operated at high idle without damage, but should never be allowed to exceed high idle rpm. Ammeter – This gauge indicates the amount of charge or discharge in the battery charging circuit. Operation of the indicator should be to the right side of “0” (zero). Fuel Level – This gauge indicates the fuel level in the fuel tank. The fuel level gauge operates when the “START/STOP” switch is in the “ON” position. Service Hour Meter – The gauge indicates operating time of the engine. This document has been printed from SPIČ. Not for Resale SEBU8311-01 29 Operation Section Features and Controls Features and Controls i02593769 Fuel Shutoff The fuel shutoff solenoid is located on the fuel injection pump. When the fuel shutoff solenoid is activated, the solenoid moves the fuel rack to the “OFF” position. Illustration 28 (1) Fuel shutoff solenoid g01305771 If an electronically controlled governor has been installed the governor operates the fuel rack in order to stop the engine. This document has been printed from SPIČ. Not for Resale 30 Operation Section Engine Starting SEBU8311-01 Engine Starting i02194223 • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls. clear. Before Starting Engine Before the engine is started, perform the required daily maintenance and any other periodic maintenance that is due. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information. • Ensure that the areas around the rotating parts are • All of the guards must be put in place. Check for damaged guards or for missing guards. Repair any damaged guards. Replace damaged guards and/or missing guards. protected against the high current drain that is created when the electric starting motor is engaged. Check electrical cables and check the battery for poor connections and for corrosion. equipped). • Disconnect any battery chargers that are not • For the maximum service life of the engine, make a thorough inspection within the engine compartment before the engine is started. Look for the following items: oil leaks, coolant leaks, loose bolts, and excessive dirt and/or grease. Remove any excess dirt and/or grease buildup. Repair any faults that were identied during the inspection. for loose clamps. • Reset all of the shutoffs or alarm components (if • Check the engine lubrication oil level. Maintain the oil level between the “ADD” mark and the “FULL” mark on the engine oil level gauge. in the header tank (if equipped). Maintain the coolant level to the “FULL” mark on the header tank. • Inspect the cooling system hoses for cracks and • Inspect the alternator and accessory drive belts for cracks, breaks, and other damage. worn wires or frayed wires. • Check the coolant level. Observe the coolant level • Inspect the wiring for loose connections and for • Check the fuel supply. Drain water from the water • If the engine is not equipped with a header tank separator (if equipped). Open the fuel supply valve (if equipped). maintain the coolant level within 13 mm (0.5 inch) of the bottom of the ller pipe. If the engine is equipped with a sight glass, maintain the coolant level in the sight glass. equipped). Service the air cleaner when the yellow diaphragm enters the red zone, or when the red piston locks in the visible position. engine has been disengaged from the engine. Minimize electrical loads or remove any electrical loads. i02665533 NOTICE All valves in the fuel return line must be open before and during engine operation to help prevent high fuel pressure. High fuel pressure may cause lter housing failure or other damage. If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air may have entered the lter housing. Also, when fuel lters have been changed, some air pockets will be trapped in the engine. In these instances, prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information on priming the fuel system. • Observe the air cleaner service indicator (if • Ensure that any equipment that is driven by the Starting the Engine Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside. Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. This document has been printed from SPIČ. Not for Resale SEBU8311-01 31 Operation Section Engine Starting Refer to the OEM manual for your type of controls. Use the following procedure to start the engine. 1. Move the throttle lever to the low idle position before you start the engine. NOTICE Do not operate the glow plugs for more than 60 seconds at one time. Damage to the glow plugs could occur. 2. Turn the engine start switch to the HEAT position. Hold the engine start switch in the HEAT position for 6 seconds until the glow plug indicator light illuminates. This will activate the glow plugs and aid in the starting of the engine. NOTICE Do not crank the engine for more than 30 seconds. Allow the electric starting motor to cool for two minutes before cranking the engine again. 3. While the glow plug indicator light is illuminated, turn the engine start switch to the START position and crank the engine. 4. When the engine starts, release the engine start switch. 5. Slowly move the throttle lever to the low idle position and allow the engine to idle. Refer to the Operation and Maintenance Manual, “After Starting Engine” topic. Note: If the glow plug indicator light illuminates rapidly for 2 to 3 seconds, or if the glow plug indicator light fails to illuminate, a malfunction exists in the cold start system. Do not use ether or other starting uids to start the engine. 6. If the engine does not start, release the engine start switch and allow the electric starting motor to cool. Then, repeat steps 2 through step 5. 7. Turn the engine start switch to the OFF position in order to stop the engine. i02177935 Starting with Jump Start Cables Improper jump start cable connections can cause an explosion resulting in personal injury. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump start cable ends to contact each other or the engine. Note: If it is possible, rst diagnose the reason for the starting failure. Make any necessary repairs. If the engine will not start only due to the condition of the battery, either charge the battery, or start the engine with jump start cables. The condition of the battery can be rechecked after the engine has been switched OFF. NOTICE Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for jump starting. The use of higher voltage will damage the electrical system. Do not reverse the battery cables. The alternator can be damaged. Attach ground cable last and remove rst. When using an external electrical source to start the engine, turn the generator set control switch to the “OFF” position. Turn all electrical accessories OFF before attaching the jump start cables. Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine being started. 1. Turn the start switch to the OFF position. Turn off all the engine’s accessories. 2. Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery. Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source. This document has been printed from SPIČ. Not for Resale 32 Operation Section Engine Starting SEBU8311-01 3. Connect one negative end of the jump start cable to the negative cable terminal of the electrical source. Connect the other negative end of the jump start cable to the engine block or to the chassis ground. This procedure helps to prevent potential sparks from igniting the combustible gases that are produced by some batteries. 4. Start the engine. 5. Immediately after the stalled engine is started, disconnect the jump start cables in reverse order. After jump starting, the alternator may not be able to fully recharge batteries that are severely discharged. The batteries must be replaced or charged to the correct voltage with a battery charger after the engine is stopped. Many batteries which are considered unusable are still rechargeable. Refer to Operation and Maintenance Manual, “Battery - Replace” and Testing and Adjusting Manual, “Battery - Test”. i01903609 After Starting Engine Note: In temperatures from 0 to 60°C (32 to 140°F), the warm-up time is approximately three minutes. In temperatures below 0°C (32°F), additional warm-up time may be required. When the engine idles during warm-up, observe the following conditions: • Check for any uid or for any air leaks at idle rpm and at one-half full rpm (no load on the engine) before operating the engine under load. This is not possible in some applications. achieve operating temperatures. Check all gauges during the warm-up period. • Operate the engine at low idle until all systems Note: Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments. Signicant changes in the readings should be investigated. This document has been printed from SPIČ. Not for Resale SEBU8311-01 33 Operation Section Engine Operation Engine Operation i02176671 i02330149 Fuel Conservation Practices The efciency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efciency in all applications. Follow the recommended procedures in order to attain optimum performance for the life of the engine. Engine Operation Correct operation and maintenance are key factors in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenance Manual are followed, costs can be minimized and engine service life can be maximized. The engine can be operated at the rated rpm after the engine reaches operating temperature. The engine will reach normal operating temperature sooner during a low engine speed (rpm) and during a low power demand. This procedure is more effective than idling the engine at no load. The engine should reach operating temperature in a few minutes. Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments. Signicant changes in the readings should be investigated. • Avoid spilling fuel. Fuel expands when the fuel is warmed up. The fuel may overow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed. • Be aware of the properties of the different fuels. Use only the recommended fuels. • Avoid unnecessary idling. Shut off the engine rather than idle for long periods of time. • Observe the air cleaner service indicator frequently. Keep the air cleaner elements clean. • Maintain the electrical systems. One damaged battery cell will overwork the alternator. This will consume excess power and excess fuel. • Ensure that the drive belts are correctly adjusted. The drive belts should be in good condition. tight. The connections should not leak. working order. • Ensure that all of the connections of the hoses are • Ensure that the driven equipment is in good • Cold engines consume excess fuel. Utilize heat from the jacket water system and the exhaust system, when possible. Keep cooling system components clean and keep cooling system components in good repair. Never operate the engine without water temperature regulators. All of these items will help maintain operating temperatures. This document has been printed from SPIČ. Not for Resale 34 Operation Section Engine Stopping SEBU8311-01 Engine Stopping i02334873 i02176672 After Stopping Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. Stopping the Engine NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and accelerated wear of the engine components. Avoid accelerating the engine prior to shutting it down. Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life. Note: Individual applications will have different control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to stop the engine. 1. Remove the load from the engine. Reduce the engine speed (rpm) to low idle. Allow the engine to idle for ve minutes in order to cool the engine. 2. Stop the engine after the cool down period according to the shutoff system on the engine and turn the ignition key switch to the OFF position. If necessary, refer to the instructions that are provided by the OEM. i01903586 • Check the crankcase oil level. Maintain the oil level between the “MIN” mark and the “MAX” mark on the engine oil level gauge. any leaks and tighten any loose bolts. • If necessary, perform minor adjustments. Repair • If the engine is equipped with a service hour meter, note the reading. Perform the maintenance that is in the Operation and Maintenance Manual, “Maintenance Interval Schedule”. • Fill the fuel tank in order to help prevent accumulation of moisture in the fuel. Do not overll the fuel tank. NOTICE Only use antifreeze/coolant mixtures recommended in the Coolant Specications that are in the Operation and Maintenance Manual. Failure to do so can cause engine damage. • Allow the engine to cool. Check the coolant level. • If freezing temperatures are expected, check the coolant for correct antifreeze protection. The cooling system must be protected against freezing to the lowest expected outside temperature. Add the correct coolant/water mixture, if necessary. driven equipment. This maintenance is outlined in the instructions from the OEM. Emergency Stopping NOTICE Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure. The OEM may have equipped the application with an emergency stop button. For more information about the emergency stop button, refer to the OEM information. Ensure that any components for the external system that support the engine operation are secured after the engine is stopped. • Perform all required periodic maintenance on all This document has been printed from SPIČ. Not for Resale SEBU8311-01 35 Operation Section Cold Weather Operation Cold Weather Operation i02717265 • Install the correct specication of engine lubricant before the beginning of cold weather. weekly. • Check all rubber parts (hoses, fan drive belts, etc) • Check all electrical wiring and connections for any fraying or damaged insulation. Cold Weather Operation Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and the operation of the diesel engine is dependent on the following items: • Keep all batteries fully charged and warm. • Fill the fuel tank at the end of each shift. • Check the air cleaners and the air intake daily. Check the air intake more often when you operate in snow. Refer to Testing and Adjusting Manual, “Glow Plug - Test”. • The type of fuel that is used • The viscosity of the engine oil • The operation of the glow plugs • Optional Cold starting aid • Battery condition This section will cover the following information: • Ensure that the glow plugs are in working order. Personal injury or property damage can result from alcohol or starting uids. Alcohol or starting uids are highly ammable and toxic and if improperly stored could result in injury or property damage. • Potential problems that are caused by cold weather operation • Suggest steps which can be taken in order to minimize starting problems and operating problems when the ambient air temperature is between 0° to−40 °C (32° to 40 °F). Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. The operation and maintenance of an engine in freezing temperatures is complex . This is because of the following conditions: • Weather conditions • Engine applications Recommendations from your Perkins dealer or your Perkins distributor are based on past proven practices. The information that is contained in this section provides guidelines for cold weather operation. • For jump starting with cables in cold weather, refer to the Operation and Maintenance Manual, “Starting with Jump Start Cables.” for instructions. Viscosity of the Engine Lubrication Oil Correct engine oil viscosity is essential. Oil viscosity affects the amount of torque that is needed to crank the engine. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended viscosity of oil. Hints for Cold Weather Operation • If the engine will start, operate the engine until a minimum operating temperature of 81 °C (177.8 °F) is achieved. Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking. for the engine do not lose heat immediately upon shutdown. This means that an engine can be shut down for a period of time and the engine can still have the ability to start readily. Recommendations for the Coolant Provide cooling system protection for the lowest expected outside temperature. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended coolant mixture. • The cooling system and the lubrication system This document has been printed from SPIČ. Not for Resale 36 Operation Section Cold Weather Operation SEBU8311-01 In cold weather, check the coolant often for the correct glycol concentration in order to ensure adequate freeze protection. • Free operation of the valves is prevented. • Valves become stuck. • Pushrods may become bent. • Other damage to valve train components can result. For this reason, when the engine is started, the engine must be operated until the coolant temperature is 71 °C (160 °F) minimum. Carbon deposits on the valve stems will be kept at a minimum and the free operation of the valves and the valve components will be maintained. In addition, the engine must be thoroughly warmed in order to keep other engine parts in better condition and the service life of the engine will be generally extended. Lubrication will be improved. There will be less acid and less sludge in the oil. This will provide longer service life for the engine bearings, the piston rings, and other parts. However, limit unnecessary idle time to ten minutes in order to reduce wear and unnecessary fuel consumption. Engine Block Heaters Engine block heaters (if equipped) heat the engine jacket water that surrounds the combustion chambers. This provides the following functions: • Startability is improved. • Warm up time is reduced. An electric block heater can be activated once the engine is stopped. An effective block heater is typically a 1250/1500 W unit. Consult your Perkins dealer or your Perkins distributor for more information. Idling the Engine When idling after the engine is started in cold weather, increase the engine rpm from 1000 to 1200 rpm. This will warm up the engine more quickly. Maintaining an elevated low idle speed for extended periods will be easier with the installation of a hand throttle. The engine should not be “raced” in order to speed up the warm up process. While the engine is idling, the application of a light load (parasitic load) will assist in achieving the minimum operating temperature. The minimum operating temperature is 82 °C (179.6 °F). The Water Temperature Regulator and Insulated Heater Lines The engine is equipped with a water temperature regulator. When the engine coolant is below the correct operating temperature jacket water circulates through the engine cylinder block and into the engine cylinder head. The coolant then returns to the cylinder block via an internal passage that bypasses the valve of the coolant temperature regulator. This ensures that coolant ows around the engine under cold operating conditions. The water temperature regulator begins to open when the engine jacket water has reached the correct minimum operating temperature. As the jacket water coolant temperature rises above the minimum operating temperature the water temperature regulator opens further allowing more coolant through the radiator to dissipate excess heat. The progressive opening of the water temperature regulator operates the progressive closing of the bypass passage between the cylinder block and head. This ensures maximum coolant ow to the radiator in order to achieve maximum heat dissipation. Note: Perkins discourages the use of all air ow restriction devices such as radiator shutters. Restriction of the air ow can result in the following: high exhaust temperatures, power loss, excessive fan usage, and reduction in fuel economy. Recommendations for Coolant Warm Up Warm up an engine that has cooled below normal operating temperatures due to inactivity. This should be performed before the engine is returned to full operation. During operation in very cold temperature conditions, damage to engine valve mechanisms can result from engine operation for short intervals. This can happen if the engine is started and the engine is stopped many times without being operated in order to warm up completely. When the engine is operated below normal operating temperatures, fuel and oil are not completely burned in the combustion chamber. This fuel and oil causes soft carbon deposits to form on the valve stems. Generally, the deposits do not cause problems and the deposits are burned off during operation at normal engine operating temperatures. When the engine is started and the engine is stopped many times without being operated in order to warm up completely, the carbon deposits become thicker. This can cause the following problems: This document has been printed from SPIČ. Not for Resale SEBU8311-01 37 Operation Section Cold Weather Operation A cab heater is benecial in very cold weather. The feed from the engine and the return lines from the cab should be insulated in order to reduce heat loss to the outside air. When Group 2 diesel fuels are used the following components provide a means of minimizing problems in cold weather: Insulating the Air Inlet and Engine Compartment When temperatures below −18 °C (−0 °F) will be frequently encountered, an air cleaner inlet that is located in the engine compartment may be specied. An air cleaner that is located in the engine compartment may also minimize the entry of snow into the air cleaner. Also, heat that is rejected by the engine helps to warm the intake air. Additional heat can be retained around the engine by insulating the engine compartment. i02322217 • Glow plugs (if equipped) • Engine coolant heaters, which may be an OEM option • Fuel heaters, which may be an OEM option • Fuel line insulation, which may be an OEM option There are three major differences between Group 1 fuels and Group 2 fuels. Group 1 fuels have the following different characteristics to Group 2 fuels. • A lower cloud point • A lower pour point Fuel and the Effect from Cold Weather Note: Only use grades of fuel that are recommended by Perkins. Refer to this Operation and Maintenance Manual, “Fluid Recommendations”. The following fuels can be used in this series of engine. • A higher energy per unit volume of fuel Note: Group 3 fuels reduce the life of the engine. The use of Group 3 fuels is not covered by the Perkins warranty. Group 3 fuels include Low Temperature Fuels and Aviation Kerosene Fuels. Special fuels include Biofuel. The cloud point is a temperature that allows wax crystals to form in the fuel. These crystals can cause the fuel lters to plug. The pour point is the temperature when diesel fuel will thicken. The diesel fuel becomes more resistant to ow through fuel lines, fuel lters,and fuel pumps. Be aware of these facts when diesel fuel is purchased. Consider the average ambient air temperature for the engine’s application. Engines that are fueled in one climate may not operate well if the engines are moved to another climate. Problems can result due to changes in temperature. Before troubleshooting for low power or for poor performance in the winter, check the fuel for waxing. Low temperature fuels may be available for engine operation at temperatures below 0 °C (32 °F). These fuels limit the formation of wax in the fuel at low temperatures. For more information on cold weather operation, refer to the Operation and Maintenance Manual, “Cold Weather Operation and Fuel Related Components in Cold Weather”. • Group 1 • Group 2 • Group 3 • Special Fuels Perkins prefer only Group 1 and Group 2 fuels for use in this series of engines. Group 1 fuels are the preferred Group of Fuels for general use by Perkins. Group 1 fuels maximize engine life and engine performance. Group 1 fuels are usually less available than Group 2 fuels. Frequently, Group 1 fuels are not available in colder climates during the winter. Note: Group 2 fuels must have a maximum wear scar of 650 micrometers (HFRR to ISO 12156-1). Group 2 fuels are considered acceptable for issues of warranty. This group of fuels may reduce the life of the engine, the engine’s maximum power, and the engine’s fuel efciency. This document has been printed from SPIČ. Not for Resale 38 Operation Section Cold Weather Operation SEBU8311-01 i01903588 Fuel Related Components in Cold Weather Fuel Tanks Condensation can form in partially lled fuel tanks. Top off the fuel tanks after you operate the engine. Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks. Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system lter is important. Drain the water and sediment from any fuel storage tank at the following intervals: weekly, oil changes, and refueling of the fuel tank. This will help prevent water and/or sediment from being pumped from the fuel storage tank and into the engine fuel tank. Fuel Filters It is possible that a primary fuel lter is installed between the fuel tank and the engine fuel inlet. After you change the fuel lter, always prime the fuel system in order to remove air bubbles from the fuel system. Refer to the Operation and Maintenance Manual in the Maintenance Section for more information on priming the fuel system. The micron rating and the location of a primary fuel lter is important in cold weather operation. The primary fuel lter and the fuel supply line are the most common components that are affected by cold fuel. Fuel Heaters Note: The OEM may equip the application with fuel heaters. If this is the case, disconnect an electric type of fuel heater in warm weather in order to prevent overheating of the fuel. If the type of fuel heater is a heat exchanger, the OEM should have included a bypass for warm weather. Ensure that the bypass is operational during warm weather in order to prevent overheating of the fuel. For more information about fuel heaters (if equipped), refer to the OEM information. This document has been printed from SPIČ. Not for Resale SEBU8311-01 39 Maintenance Section Rell Capacities Maintenance Section Rell Capacities i02959059 403D-07 Engine Table 12 403C-07 Engine Rell Capacities Compartment or System Minimum 2.35 L (2.5 qt) Maximum 3.05 L (3.2 qt) Rell Capacities Lubrication System The rell capacities for the engine crankcase reect the approximate capacity of the crankcase or sump plus standard oil lters. Auxiliary oil lter systems will require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil lter. Refer to the Operation and Maintenance Manual, “Maintenance Section” for more information on Lubricant Specications. Crankcase Oil Sump(1) Total Lubrication System(2) (1) These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil lters. Engines with auxiliary oil lters will require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil lter. (2) The Total Lubrication System includes the capacity for the Crankcase Oil Sump plus the capacity of factory installed oil lters and other lters added to the lubrication system. Enter the value for the capacity of the Total Lubrication System in this row. 403D-11 Engine Table 13 402D-05 Engine Table 11 403D-11 Engine Rell Capacities Compartment or System Minimum 3.4 L (3.6 qt) Maximum 4.4 L (4.6494 qt) 402D-05 Engine Rell Capacities Compartment or System Crankcase Oil Sump(1) Total Lubrication System(2) (1) Crankcase Oil Sump(1) Maximum 2.01 L (2.1 qt) Total Lubrication System(2) (1) Minimum 1.61 L (1.7 qt) These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil lters. Engines with auxiliary oil lters will require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil lter. (2) The Total Lubrication System includes the capacity for the Crankcase Oil Sump plus the capacity of factory installed oil lters and other lters added to the lubrication system. Enter the value for the capacity of the Total Lubrication System in this row. These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil lters. Engines with auxiliary oil lters will require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil lter. (2) The Total Lubrication System includes the capacity for the Crankcase Oil Sump plus the capacity of factory installed oil lters and other lters added to the lubrication system. Enter the value for the capacity of the Total Lubrication System in this row. 403D-15 and 403D-15T Engines Table 14 403D-15 and 403D-15T Engines Rell Capacities Compartment or System Crankcase Oil Sump(1) Total Lubrication System(2) (1) Minimum 4.5 L (4.8 qt) Maximum 6 L (6.3 qt) These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil lters. Engines with auxiliary oil lters will require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil lter. (2) The Total Lubrication System includes the capacity for the Crankcase Oil Sump plus the capacity of factory installed oil lters and other lters added to the lubrication system. Enter the value for the capacity of the Total Lubrication System in this row. This document has been printed from SPIČ. Not for Resale 40 Maintenance Section Rell Capacities SEBU8311-01 403D-17 Engine Table 15 404D-22, 404D-22T and 404D-22TA Engines Table 17 403D-17 Engine Rell Capacities Compartment or System Crankcase Oil Sump(1) Total Lubrication System(2) (1) Minimum 4.5 L (4.8 qt) Maximum 6 L (6.3 qt) 404D-22, 404D-22T and 404D-22TA Engines Rell Capacities Compartment or System Crankcase Oil Sump(1) Total Lubrication System(2) (1) Minimum 8.9 L (9.4 qt) Maximum 10.6 L (11.2 qt) These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil lters. Engines with auxiliary oil lters will require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil lter. (2) The Total Lubrication System includes the capacity for the Crankcase Oil Sump plus the capacity of factory installed oil lters and other lters added to the lubrication system. Enter the value for the capacity of the Total Lubrication System in this row. 404D-15 Engine Table 16 More than one style of sump may be used on these engines. Use these values to estimate the rell capacity. Use the engine oil level gauge to ll the engine to the correct oil level. Record the result in this table. These values are the approximate capacities for the Crankcase Oil Sump which includes the standard factory installed oil lters. Engines with auxiliary oil lters will require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil lter. (2) The Total Lubrication System includes the capacity for the Crankcase Oil Sump plus the capacity of factory installed oil lters and other lters added to the lubrication system. Enter the value for the capacity of the Total Lubrication System in this row. 404D-15 Engine Rell Capacities Compartment or System Crankcase Oil Sump(1) Total Lubrication System(2) (1) Cooling System Maximum 5.6 L (5.9175 qt) Minimum 3.9 L (4.1211 qt) These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil lters. Engines with auxiliary oil lters will require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil lter. (2) The Total Lubrication System includes the capacity for the Crankcase Oil Sump plus the capacity of factory installed oil lters and other lters added to the lubrication system. Enter the value for the capacity of the Total Lubrication System in this row. To maintain the cooling system, the Total Cooling System capacity must be known. The approximate capacity is for the engine cooling system. External System capacities will vary among applications. Refer to the OEM specications for the External System capacity. This capacity information will be needed in order to determine the amount of coolant that is required for the Total Cooling System. 402D-05 Engine Table 18 402D-05 Engine Rell Capacities Compartment or System Engine Only External System Per OEM(1) Total Cooling System(2) (1) Liters 1.1 Quarts 1.2 The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM specications. Enter the value for the capacity of the External System in this row. (2) The Total Cooling System capacity includes the capacity of the Engine plus the External System. Enter the value for the capacity of the Total Cooling System in this row. This document has been printed from SPIČ. Not for Resale SEBU8311-01 41 Maintenance Section Rell Capacities 403D-07 Engine Table 19 404D-15 Engine Table 22 403D-07 Engine Rell Capacities Compartment or System Engine Only External System Per Total Cooling (1) 404D-15 Engine Rell Capacities Quarts 1.3 Compartment or System Engine Only External System Per (1) Liters 1.2 Liters 2.4 Quarts 2.5 OEM(1) OEM(1) System(2) Total Cooling System(2) The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM specications. Enter the value for the capacity of the External System in this row. (2) The Total Cooling System capacity includes the capacity of the Engine plus the External System. Enter the value for the capacity of the Total Cooling System in this row. The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM specications. Enter the value for the capacity of the External System in this row. (2) The Total Cooling System capacity includes the capacity of the Engine plus the External System. Enter the value for the capacity of the Total Cooling System in this row. 403D-11 Engine Table 20 404D-22, 404D-22T and 404D-22TA Engines Table 23 403D-11 Engine Rell Capacities Compartment or System Engine Only External System Per OEM(1) Total Cooling System(2) (1) Liters 1.9 Quarts 2.0 404D-22,404D-22T and 404D-22TA Engines Rell Capacities Compartment or System Engine Only External System Per (1) Liters 3.6 Quarts 3.8 OEM(1) The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM specications. Enter the value for the capacity of the External System in this row. (2) The Total Cooling System capacity includes the capacity of the Engine plus the External System. Enter the value for the capacity of the Total Cooling System in this row. Total Cooling System(2) The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM specications. Enter the value for the capacity of the External System in this row. (2) The Total Cooling System capacity includes the capacity for the Engine plus the External System. Enter the value for the capacity of the Total Cooling System in this row. 403D-15 and 403D-15T Engines Table 21 i02959104 403D-15 and 403D-15TEngines Rell Capacities Compartment or System Engine Only External System Per OEM(1) Total Cooling System(2) (1) Fluid Recommendations Quarts 2.7 Liters 2.6 General Lubricant Information Because of government regulations regarding the certication of exhaust emissions from the engine, the lubricant recommendations must be followed. The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM specications. Enter the value for the capacity of the External System in this row. (2) The Total Cooling System capacity includes the capacity of the Engine plus the External System. Enter the value for the capacity of the Total Cooling System in this row. Engine Manufacturers Association (EMA) Oils The “Engine Manufacturers Association Recommended Guideline on Diesel Engine Oil” is recognized by Perkins. For detailed information about this guideline, see the latest edition of EMA publication, “EMA DHD -1”. This document has been printed from SPIČ. Not for Resale 42 Maintenance Section Rell Capacities SEBU8311-01 API Oils The Engine Oil Licensing and Certication System by the American Petroleum Institute (API) is recognized by Perkins. For detailed information about this system, see the latest edition of the “API publication No. 1509”. Engine oils that bear the API symbol are authorized by API. Engine Oil Commercial Oils The performance of commercial diesel engine oils is based on American Petroleum Institute (API) classications. These API classications are developed in order to provide commercial lubricants for a broad range of diesel engines that operate at various conditions. Only use commercial oils that meet the following classications: • EMA DHD-1 multigrade oil (preferred oil) • API CH-4 multigrade oil (preferred oil) • ACEAE5 In order to make the correct choice of a commercial oil, refer to the following explanations: Illustration 29 Typical API symbol g00546535 Diesel engine oils CC, CD, CD-2, and CE have not been API authorized classications since 1 January 1996. Table 24 summarizes the status of the classications. Table 24 API Classications Current CF-4, CG-4, CH-4 CF CF-2(1) (1) Obsolete CE CC, CD CD-2(1) EMA DHD-1 – The Engine Manufacturers Association (EMA) has developed lubricant recommendations as an alternative to the API oil classication system. DHD-1 is a Recommended Guideline that denes a level of oil performance for these types of diesel engines: high speed, four stroke cycle, heavy-duty, and light duty. DHD-1 oils may be used in Perkins engines when the following oils are recommended: API CH-4, API CG-4, and API CF-4. DHD-1 oils are intended to provide superior performance in comparison to API CG-4 and API CF-4. DHD-1 oils will meet the needs of high performance Perkins diesel engines that are operating in many applications. The tests and the test limits that are used to dene DHD-1 are similar to the new API CH-4 classication. Therefore, these oils will also meet the requirements for diesel engines that require low emissions. DHD-1 oils are designed to control the harmful effects of soot with improved wear resistance and improved resistance to plugging of the oil lter. These oils will also provide superior control of piston deposits for engines with either two-piece steel pistons or aluminum pistons. All DHD-1 oils must complete a full test program with the base stock and with the viscosity grade of the nished commercial oil. The use of “API Base Oil Interchange Guidelines” are not appropriate for DHD-1 oils. This feature reduces the variation in performance that can occur when base stocks are changed in commercial oil formulations. The classications CD-2 and American Petroleum Institute CF-2 are for two-cycle diesel engines. Perkins does not sell engines that utilize CD-2 and API CF-2 oils. Terminology Certain abbreviations follow the nomenclature of “SAE J754”. Some classications follow “SAE J183” abbreviations, and some classications follow the “EMA Recommended Guideline on Diesel Engine Oil”. In addition to Perkins denitions, there are other denitions that will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in this publication, “Fluid Recommendations/Engine Oil” topic (Maintenance Section). This document has been printed from SPIČ. Not for Resale SEBU8311-01 43 Maintenance Section Rell Capacities DHD-1 oils are recommended for use in extended oil change interval programs that optimize the life of the oil. These oil change interval programs are based on oil analysis. DHD-1 oils are recommended for conditions that demand a premium oil. Your Perkins dealer or your Perkins distributor has the specic guidelines for optimizing oil change intervals. API CH-4 – API CH-4 oils were developed in order to meet the requirements of the new high performance diesel engines. Also, the oil was designed to meet the requirements of the low emissions diesel engines. API CH-4 oils are also acceptable for use in older diesel engines and in diesel engines that use high sulfur diesel fuel. API CH-4 oils may be used in Perkins engines that use API CG-4 and API CF-4 oils. API CH-4 oils will generally exceed the performance of API CG-4 oils in the following criteria: deposits on pistons, control of oil consumption, wear of piston rings, valve train wear, viscosity control, and corrosion. Three new engine tests were developed for the API CH-4 oil. The rst test specically evaluates deposits on pistons for engines with the two-piece steel piston. This test (piston deposit) also measures the control of oil consumption. A second test is conducted with moderate oil soot. The second test measures the following criteria: wear of piston rings, wear of cylinder liners, and resistance to corrosion. A third new test measures the following characteristics with high levels of soot in the oil: wear of the valve train, resistance of the oil in plugging the oil lter, and control of sludge. In addition to the new tests, API CH-4 oils have tougher limits for viscosity control in applications that generate high soot. The oils also have improved oxidation resistance. API CH-4 oils must pass an additional test (piston deposit) for engines that use aluminum pistons (single piece). Oil performance is also established for engines that operate in areas with high sulfur diesel fuel. All of these improvements allow the API CH-4 oil to achieve optimum oil change intervals. API CH-4 oils are recommended for use in extended oil change intervals. API CH-4 oils are recommended for conditions that demand a premium oil. Your Perkins dealer or your Perkins distributor has specic guidelines for optimizing oil change intervals. Some commercial oils that meet the API classications may require reduced oil change intervals. To determine the oil change interval, closely monitor the condition of the oil and perform a wear metal analysis. NOTICE Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear. Total Base Number (TBN) and Fuel Sulfur Levels for Diesel Engines The Total Base Number (TBN) for an oil depends on the fuel sulfur level. For engines that use distillate fuel, the minimum TBN of the new oil must be 10 times the fuel sulfur level. The TBN is dened by “ASTM D2896”. The minimum TBN of the oil is 5 regardless of fuel sulfur level. Illustration 30 demonstrates the TBN. Illustration 30 g00799818 (Y) TBN by “ASTM D2896” (X) Percentage of fuel sulfur by weight (1) TBN of new oil (2) Change the oil when the TBN deteriorates to 50 percent of the original TBN. Use the following guidelines for fuel sulfur levels that exceed 1.5 percent: • Choose an oil with the highest TBN that meets one of these classications: EMA DHD-1 and API CH-4. • Reduce the oil change interval. Base the oil change interval on the oil analysis. Ensure that the oil analysis includes the condition of the oil and a wear metal analysis. Excessive piston deposits can be produced by an oil with a high TBN. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore. NOTICE Operating diesel engines with fuel sulphur levels over 0.5 percent will require shortened oil change intervals in order to help maintain adequate wear protection. This document has been printed from SPIČ. Not for Resale 44 Maintenance Section Rell Capacities SEBU8311-01 Table 25 Percentage of Sulfur in the fuel Lower than 0.5 0.5 to 1.0 Greater than 1.0 Oil change interval Normal 0.75 of normal 0.50 of normal Some synthetic base oils have performance characteristics that enhance the service life of the oil. Perkins does not recommend the automatic extending of the oil change intervals for any type of oil. Re-rened Base Stock Oils Re-rened base stock oils are acceptable for use in Perkins engines if these oils meet the performance requirements that are specied by Perkins. Re-rened base stock oils can be used exclusively in nished oil or in a combination with new base stock oils. The US military specications and the specications of other heavy equipment manufacturers also allow the use of re-rened base stock oils that meet the same criteria. The process that is used to make re-rened base stock oil should adequately remove all wear metals that are in the used oil and all the additives that are in the used oil. The process that is used to make re-rened base stock oil generally involves the process of vacuum distillation and hydrotreating the used oil. Filtering is adequate for the production of high quality, re-rened base stock oil. Lubricant Viscosity Recommendations The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation. Refer to Table 26 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine. Refer to Table 26 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated. Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up. Table 26 Lubricants for Cold Weather When an engine is started and an engine is operated in ambient temperatures below −20 °C (−4 °F), use multigrade oils that are capable of owing in low temperatures. These oils have lubricant viscosity grades of SAE 0W or SAE 5W. When an engine is started and operated in ambient temperatures below −30 °C (−22 °F), use a synthetic base stock multigrade oil with an 0W viscosity grade or with a 5W viscosity grade. Use an oil with a pour point that is lower than −50 °C (−58 °F). The number of acceptable lubricants is limited in cold weather conditions. Perkins recommends the following lubricants for use in cold weather conditions: First Choice – Use oil with an EMA DHD-1 Recommended Guideline. Use a CH-4 oil that has an API license. The oil should be either SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 lubricant viscosity grade. Second Choice – Use an oil that has a CH-4 additive package. Although the oil has not been tested for the requirements of the API license, the oil must be either SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40.
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